EPPM 16.3

April / May 2014

Volume 16 Issue 3

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IN THIS ISSUE MACHINERY

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MARKETS: Compounding

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ISSN No - 2052-3912 APRIL / MAY 2014 • WWW.EPPM.COM • 3

“

FROM THE EDITOR

Smart factories: we’re not as far off as you might think “Smart factories” is a term which is quickly becoming established as a handy umbrella phrase for digital integration with the manufacturing process. From big data to smartphone apps, if you believe the software companies, in just a few years we’ll all be manufacturing in a quiet hum of efficiency, accuracy and flawless timing.

But for many SMEs, this seems unrealistic - and uneccessary. Where margins are critical, performing a complete software and process control upgrade, including ERP, MES and so on could be at the very bottom of the long-term business plan. Not to mention the time and investment required for re-training.

But who’s to say that all of that is necessary. Others would argue that a few small measures would have a huge impact on streamlining, with minimal effect on cash flow.

In recent years, we’ve seen many of the processing machinery manufacturers launching free apps for

4 • WWW.EPPM.COM • APRIL / MAY 2014

smartphones - often seen as a simple and effective way of integrating digital control into newer machines. But, of course, a newer machine (or at least a newer control system) is often a prerequisite for this kind of capability.

Arburg, during its recent open house event, discussed ‘Industry 4.0’ - the German government’s own platform for approaching the ‘Smart Factory’ headon. The group’s first major foray into this area looks at the use of printing for networking resources - both human and machine. It aims to tackle issues of traceability, accountability and quality management, and there are already some impressive examples of it in use.

More details can be found in the review of Arburg’s Technology Days in this issue.

Again, for some, the technology may still seem like a distant prospect, and unnecessary for some firms.

However, it could also be viewed as the natural progression from the already prevalent use of barcodes, batch numbers and tracking references. And simpler, too!

Production systems have evolved greatly over the years, and whilst the software giants are certainly guilty of exploiting the next stage of evolution as a means to enter the manufacturing marketplace, the next stage is probably not far off for many manufacturers.

In other news, this issue looks at mould and tool innovations, the latest developments in blow moulding (which includes the new launch from Kautex), packaging applications plus an interesting insight into the compounding industry from one of the world’s major compounders - PolyOne.

David Gray, Editor

Cover Story

ALBIS PROVES

MARKET EXPERTISE AND PROJECT-BASED APPROACH CASE STUDY – Automotive A leading international Tier 1 automotive supplier has approached materials compounder and distributor ALBIS to support in designing, specifying and producing an appropriate product for an air filter to be used under the bonnet. The project required material selection advice followed by Moldflow to assess gate positions and optimal material flow properties. Secondary project management was provided by the ALBIS team in France liaising with the Tier 1 project leader. The material specification and approval was completed in the UK followed by tool trials

ALBIS History ALBIS UK has been established in the UK and Irish markets for 48 years and is a subsidiary of ALBIS Plastics GmbH, one of the largest distributors and thermoplastic compounders in Europe.

With a strong network across Europe and a growing footprint into North Africa, the USA and Asia, ALBIS is able to provide its customers with solutions

whether it is on a local or global level.

Increasingly customers turn to ALBIS for support on a wide range of technical, specific market–related and regulatory issues. ALBIS says that technical support has always been a cornerstone of its offering to its customers as well as the ‘one-stop-shop’ approach offered with its extensive portfolio of products.

experts focussing on the healthcare, automotive, electrical & electronic and packaging markets.

With increasing regulation of some sectors, this specific knowledge is vital to ensure the right materials are selected and the appropriate support provided.

Technical support available regionally With an experienced local UK field-based team of plastics engineers, practical advice and support is available to customers on a wide range of issues.

More and more the group is finding that this support is required on an international basis, and ALBIS says it is used to supporting such requests.

Extensive product portfolio In recent years the ALBIS UK product portfolio has been developed and strengthened, and the group says that it now provides a class–leading offering. The company can offer products for a glasslike appearance, high temperature performance, chemical and impact resistance, metal replacement, postconsumer recycled products, and more.

Plastics provide designers with an almost endless array of solutions and the ALBIS range, which includes many of the world’s “famous brands” brings them close to the market. Added to the distribution portfolio is ALBIS’ own range of manufactured brands and this ability to compound has long been a service that differentiates ALBIS and provides customers with a high degree of flexibility.

With such an extensive portfolio ALBIS says it is well positioned to give impartial material selection advice ensuring the right material is selected for the job, depending on customer requirements.

Market expertise The ALBIS range offers products for every sector of industry and a host of applications, from the very simple to the highly sophisticated and specified materials. Increasingly, ALBIS says it has recognised the need to develop its expertise in specific market sectors and as a result is able to offer customers product ranges tailored to their individual requirements along with the necessary regulatory, compliance and sustainability requirements specific to their sector. Business teams have been created within ALBIS lead by industry

ALBIS provide solutions for many automotive applications including interior and exterior and under the bonnet.

supported by ALBIS Far East in China and Taiwan. Final tool commissioning took place at the UK manufacturing location including part production for OEM sign off.

With its global network ALBIS was able to recommend a suitable talc–filled PP from its ALTECH range, give tooling advice after running Moldflow and provide on-site engineering technical assistance at all four locations ensuring the customer was supported fully at every step of the project. The project was started on time with ALBIS UK, which is now manufacturing the compound in Knutsford, Manchester.

Project-based approach ALBIS is used to working with its customers in a project-based way and says it is often regarded as part of its clients’ own project teams. Impartial advice and expert knowledge means that customers recognise the value of involving a materials expert early in their projects to avoid costly mistakes which are difficult to remedy.

ALBIS also brings a consistent and reliable approach to the market as it has been representing many of the producers it distributes for almost 50 years. This builds a wealth

Technical input is provided at an early stage in the project.

The ALBIS medical portfolio is extensive and class leading. of knowledge which can be applied to the project and also ensures that projects which take many years to come to market get a consistent approach.

Distribution and compounding Added flexibility for customers is provided by ALBIS’ ability to not only distribute products but also compound those products. ALBIS has its own extensive range of compounds but also produces under license for world class producers such as Bayer MaterialScience, Lanxess, BASF and Styrolution. This allows colour and lot size flexibility as well as the ability to customise as required.

ALBIS Web: www.albis.com APRIL / MAY 2014 • WWW.EPPM.COM • 5

MACHINERY

Article

IN THE HEART OF THE BLACK FOREST, THERE LIES...

ARBURG If you’re an injection moulder, and you haven’t visited Arburg’s headquarters in Lossburg, Germany - you should. This year’s annual ‘Technology Days’ event allowed customers a unique insight into the culture of innovation thriving at the centre of the rural surroundings of the Black Forest.

As headquarters go, it’s not your traditional establishment. Sporting a gleaming glass-front, the image is clean, contemporary and distinctive, and yet rather than sitting alongside an industrial estate, with the nearby buzz of a motorway, Arburg is nestled comfortably in the traditional and historical town of Lossburg, with stunning views of the forest, and a population of just over 7000.

But this is EPPM, not a holiday brochure - so let’s get back to business.

Innovation past, present and future While the surroundings may be traditional, it’s clear that Arburg is as forward-thinking as ever. The innovations on display at this year’s event were not just aimed at current needs, but also at future applications.

That said, the group has retained a strong connection to its beginnings, in the form of the recently revamped ‘Evolution’ exhibit. Speaking during the press conference, Michael Hehl, Managing Partner at Arburg said: “The completely redesigned “Evolution” exhibit allows visitors to experience the history of Arburg interactively on an area of around 770 metres squared. The exhibit includes machines, innovations and plastic parts going back 90 years, as well as a wide range of multimedia content covering company and product development, the brand and trade fairs, as well as contemporary history and visions of the future.”

The Freeformer On the subject of future applications, Arburg gave visitors a chance to get even closer to the soon-to-be-released Freeformer. The machine, which is based on additive manufacturing principles, made waves at last year’s K Show, with its launch opening the event.

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“

The development of the freeformer does not mean that we are neglecting the injection moulding sector.”

- Michael Hehl, Managing Partner, Arburg

Arburg says it wanted to show that the Freeformer fits into the existing product range, whilst opening up new opportunities for product design and the efficient production of one-off parts or small-volume batches. During the event, one and two-component parts were manufactured, including an ABS connector housing as a spare part for an Allrounder injection moulding machine, and a housing for the main switch of the Freeformer itself.

However, Hehl was keen to emphasise that the firm’s roots remain firmly in the injection moulding arena. “The development of the Freeformer does not mean that we are neglecting the injection moulding sector. Quite the contrary: with more than 40 Allrounder exhibits and a wide range of applications and industries, we will be presenting innovations, highlights and a representative cross-section of our current range over the next four days”, said Hehl.

Investment in facilities Hehl confirmed plans for moving in to Arburg’s new two-storey expansion will take place in Autumn 2015. The capital investment, which amounts to tens of millions of euros, will expand the assembly area for large Allrounders up to 5,000 kN, as well as housing other projects. It will have a useable floorspace of around 18,600 m², increasing the floorspace at the Lossburg factory by some 13% to just under 165,000 m².

And it’s not just the HQ that’s growing.

The new firm has already announced plans for a new US HQ in Connecticut, which will cover 2,500 m² and is being constructed in Rocky Hill, six miles from the previous Newington site.

The firm’s Polish subsidiary will also receive its own building with a floorspace of 800 m², and in the Czech Republic, the existing building is being expanded significantly in order to increase capacity for growing demand.

Article Particle-foam composite injection moulding On display during the event was a turnkey system for particle-foam composite injection moulding (PCIM), featuring a two-component Allrounder 470 S with a clamping force of 1,100 kN. Product handling was done by a mobile Agilus six-axis robotic system with Selogica user interface from Kuka, which was moving on a further linear axis allowing for fast entry into the mould, and short cycle times.

cooling times and therefore reduced cycle times. The 65-gram component was produced on an electric Allrounder 470 E with a clamping force of 1,000 kN in a cycle time of around 60 seconds.

The Selogica control system enables switching from material injection to gas injection as a function of time, distance or pressure.

Industry 4.0 The German government has introduced Industry 4.0 for the future of manufacturing. In response, Arburg has made plans based on the evolutionary concept of a ‘smart factory’, which would require data integration of machines, order information and process data

collectively. The group used a simple toy buggy as an application to illustrate Industry 4.0 in effect.

In the buggy application, a unique QR code is used to call up all important process parameters for the buggy. The

Arburg host computer system networks various independent stations, recording all the parameters and transmitting them to a web server.

“We are taking the Technology Days as an opportunity to demonstrate that Continued on page 8

With a load-bearing capacity of 6 or 10 kilograms and ranges of up to 1,100 millimetres, the new robotic system has been designed specifically for plastics processing jobs.

First, it removes tyres made of expanded polypropylene (EPP) from a magazine and inserts them into the mould — the PP wheel rims are then moulded on. A firm, permanent mechanical bond is created through controlled melting of the surface of the foamed insert. The premoulded parts are then transferred to the second cavity and the tyres are overmoulded with the soft TPE component. The cycle time for this is 40 seconds. The robotic system removes the finished parts and transfers them to a system that automatically packs the completed wheels into individual bags and prints them during the running process.

Fluid injection technology The weight of thick-walled components can be significantly reduced using fluid injection technology (FIT), in which gas (GIT) or water (WIT) is introduced into the cavity. Rod-shaped components with very large wall thicknesses such as handles are especially suited to gas injection technology.

Using a plastic garden trowel as a sample part, the group demonstrated how significant material savings can be achieved by creating a hollow space in the handle using nitrogen. The smaller wall thicknesses also result in shorter APRIL / MAY 2014 • WWW.EPPM.COM • 7

MACHINERY Arburg has already started the journey towards the smart factory. We can individualise every component and trace it at every point in its production. This ensures transparency,” said Michael Vieth, Group Manager Technical Coordination at Arburg.

Personalised production Visitors were able to have their own buggy produced for them. For this they first received a personalised chip card with a username of their choice at a data entry terminal. When the visitor is ready, the card was read into the Selogica control system of the production cell.

A hydraulic Allrounder 370 S produced the buggy in the next cycle. A new, fast-entry Multilift V robotic system removed the product and transferred it to a downstream laser printing system, which applied an individualised QR code onto the roof of the toy car. At the same time, the Selogica control system transferred the relevant product data to the Arburg host computer system (ALS). This enabled the process parameters to be assigned at a later point, so that all process steps can

Article be documented error-free on an end-toend basis.

The next step involved the visitors building their own personal buggy from four individual parts. A downstream camera test station documented whether or not the roof, front and rear axles had been mounted correctly on the chassis.

Finally, a “test run” measured the speed achieved by the buggy as it rolled down a ramp. The Arburg host computer system recorded and archived the test results and transmitted the data to a web server.

An industrial handheld scanner can be used to read the buggy’s QR code. The visitor’s name would then feature on a part-specific internet page showing all the process data for their unique moulded part. Details of the time, cycle counter, cycle time and various injection moulding parameters and ambient temperature, humidity, speed, dimensions and photos from the camera inspection could all be viewed online. All of this information can also be retrieved later from home via smartphone.

Packaging Rather than using applications for large unit volumes, as is typical of the packaging industry, Arburg displayed an alternative that offers an efficient system for medium unit volumes. An electric Allrounder 570 A was producing a pair of 6.4 gram tubs from PP in a cycle time of 3.6 seconds. The automation consisted of a Multilift V from Arburg, which was equipped with a new dynamic mouldentry axis. This allowed the ‘action time’ in the mould to be reduced by 25% in comparison with a standard robotic system.

Arburg also exhibited a hybrid Allrounder 570 A (the “packaging” version) for the high-speed production of rectangular thin-walled 1-litre tubs in a cycle time of around 3 seconds. The high-performance machine with a clamping force of 1,800 kN has developed over time to become “a complete, high-performance solution”, says Arburg.

Medical A GMP-compliant stainless steel Allrounder was used in a class 7 cleanroom, with a clean air module above the clamping unit to ensure clean production conditions. A mould made by Männer was used to produce two 2.35 gram syringe barrels from COP (cyclic olefin polymer) with a cycle time of around nine seconds. This involved lateral injection via a needle shut-off nozzle. COP is transparent and has similar barrier properties to glass, but is also almost unbreakable and cost-efficient to produce. In a subsequent step, the syringe barrels can be pre-filled, assembled and packaged ready for use.

The second electric Allrounder 370 A is also designed to meet the high quality standards required for the mass-production of medical parts. During the Technology Days, 64 pipette tips per cycle were produced on a high-performance mould from Tanner in a cycle time of 4.4 seconds.

Optics For the field of optics, Arburg produced 25 millimetre thick lenses from polycarbonate in several stages in a short cycle time, using an electric two-component Allrounder 520 A with a clamping force of 1,500 kN. The machine was equipped with a multi-timed rotary mould from Weber featuring three injection stations, four cooling stations and one removal station.

Movement to the stations is carried out by means of an electric rotary unit in 45° steps.

A size 70 vertical injection unit injects the first layer at the first station. This is then cooled in three subsequent positions. In the fifth station, this layer is overmoulded

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with the second component of the same material. This involves a size 400 horizontal injection unit. Cooling again takes place in the next station before the third component is injected, also horizontally. The finished three-layered lens is then removed from the closed mould in the eighth and final position.

By producing the lens using multi-component injection moulding in three layers, with four cooling steps in simultaneous processes in the mould, the cycle time can be reduced to around 55 seconds.

The complete mould sequence, including the rotational movement, is fully integrated in the Selogica control system. In this example, the six-axis robotic system is directly connected to the machine control and can be programmed by the operator using Selogica user interface. It removes the finished moulded lenses and transfers them to an optical inspection station before being set down.

Record-breaking attendance In all, Arburg’s 2014 Technology Days were a success for the company, and allowed clients to see into the firm’s innovative plans for the future. Approximately 6,900 visitors attended - a record figure for the event.

Arburg says that around 45% of these came from abroad, the majority of which came from Europe, with 260 guests from the USA, and 185 making the trip from China. If you didn’t make it this year, stay tuned for details of the 2015 event — it’s well worth the trip to the Black Forest.

MACHINERY

Moulds & Tooling

Proto Labs supplies 10,000 moulds into Europe Proto Labs, which claims to be “the world’s fastest manufacturer of CNC machined and injection moulded parts”, has announced the production of its 10,000th mould in Europe. This 10,000th mould has been produced for the French company PETZL as part of the group’s Protomold injection moulding service.

John Tumelty, Managing Director of Proto Labs in Europe, commented: “The manufacture of the 10,000th mould in Europe represents an important milestone and demonstrates the dynamism of Proto Labs, which has had a presence in Europe for eight years.”

Bernard Faure, Technical Sales Manager responsible for France added, “I am truly delighted that this 10,000th mould has been produced for a firm which is a leader in its field, based in the RhôneAlpes region just half an hour away from our office here in France.”

Raphaël Lanez said: “The test piece to be used for our tests was produced very rapidly in CAD and then the parts were delivered in record time by Proto Labs. I don’t know what technology Proto Labs uses to manufacture moulds so quickly; their service is simply incredible.”

Before discovering Proto Labs’ Protomold service, Raphaël Lanez used to produce prototypes by sintering. He added: “Today, thanks to the “production-intent material” prototype parts supplied by Protomold, we are saving a huge amount of time - around two to three months - for validating the

tests. Proto Labs’ services have enabled us to create a validation protocol, something that we could not have done previously. For us, it was the key to solving our problems”.

“The Proto Labs team in France is very efficient, very on the ball, very professional and, at the same time, they are friendly people to work with. I have particularly appreciated their customer service, their flexibility and obviously the quick turnaround. I have already called upon Proto Labs for other projects, and will not hesitate to use their services again.”

Proto Labs’ online quoting system ProtoQuote (for injection moulded parts) and FirstQuote (for CNC machined parts) deliver a cost and manufacturability analysis quotation accessed via the group’s websites. After loading a 3D CAD part, the customer receives a nontechnical quote, incorporating costs, material choices and (where appropriate) suggestions for changes to parts in order to improve manufacturability and/or tooling and part cost.

Proto Labs Web: www.protolabs.co.uk

Founded in 1976 in Crolles, PETZL is a family business employing around 500 people. The company designs tools and accessories for sportsmen, women and professionals, enabling them to tackle the most inaccessible vertical environments, by day or night. This includes equipment such as protective helmets, lamps, harnesses, carabiners, etc., used in sports such as rock climbing and mountaineering and also by professionals working at heights – such as tree surgeons, rescue personnel, oil platform workers, and utility company operatives.

PETZL’s first contact with Proto Labs was in 2011, via one of the group’s partners, an external design office. Since then, the firm has regularly used Proto Labs’ Protomold service.

The 10,000th mould manufactured by Proto Labs in Europe was created for Raphaël Lanez, head of the helmet development unit at PETZL, in order to carry out tests to measure the effect of chemical products on the materials of which the protective helmets are made.

Test pieces needed to be produced quickly in order to expose them to complex environments and observe the impact of those environments on the mechanical properties of the materials used.

APRIL / MAY 2014 • WWW.EPPM.COM • 9

MACHINERY

Moulds & Tooling

Software gives UK moulder advanced flexibility UK injection moulder Rutland Plastics has used the Vero Group’s ‘VISI’ software in combination with an Objet 3D printer to design and manufacture a secondary operation jig which halved the manpower required for the shop floor assembly.

Technical Manager Carl Martin said: “Any good engineer can see it’s not just a CAD/CAM system for creating injection moulding tools; it’s an extremely powerful system for anything in the design world. We use it for designing a number of different items throughout the business, from a small jig, through to a complete multi-impression mould tool.”

He says VISI’s role in ensuring the company could competitively produce a pipe coupling for the drainage industry is an example of its versatility. “We used VISI to create a 3D printed prototype of the coupling, the mould tool for production, and a unique jig to automate a manual part of the operation.”

Carl Martin says the mesh functionality within VISI was a useful tool when preparing the model geometry for printing on the Objet Connex 350. The mesh feature set provides tools to cleanup problematic vertices, simplify, fill holes and analyse the mesh topology. Printing

a fit-for-purpose prototype meant the customer could fit prototype physical model to the pipes, ensuring it functioned as expected, before having the mould tool built. “It’s expensive to change tooling if the moulded part isn’t correct. The 3D printed part worked perfectly, so we then moved forward with building the injection mould tool in VISI.” As the part had already been designed in VISI, it was a CAD through CAM process to manufacture the mould in P20 hardened tool steel. VISI Mould’s essential model preparation tools inspect the model data for moulding feasibility, while draft analysis interrogates the model to identify any potential design issues. “We used the split line and plane creation function for the two cavities, and then built up the ancillaries around that to design the tool as a whole. It meant we could be sure of the accuracy of each individual aspect – namely the cavity plates, the backing plate, the ejector system, the risers and the clamping plates.”

VISI Flow’s injection simulation showed optimum moulding conditions by identifying the ideal locating gate positions. “It was vital for us to verify where the part needed to be gated, which areas may be difficult to fill, and where venting needed to be placed into the tool. VISI Flow showed us how the tool would perform on the moulding machine.”

The HDPE component links two pieces of pipe by electrofusion, using special fittings that have built-in electric heating elements which are used to weld the joint together. In order to be successfully welded in the field, brass continuity pins have to be inserted before the part is shipped out of the factory. “Originally we had one operator managing the turning and wire laying, with a second person manually inserting the pins which hold the wire in place.”

Automating the pinning process and reducing manpower from two to one was a key requirement.

“We used VISI to design the jig to handle this job, from the ground up.

VISI created the components and animated all movements showing how it would function on the shop floor.”

The suite of VISI in use at Rutland also includes VISI PEPSWire, VISI Electrode and VISI Machining 3D, all of which, Vero says, play an equally vital role in the production process, programming two Bridgeport VMC mills, a Fanuc Robocut 1ia wire eroder and a AgieCharmilles Roboform 30 spark eroder.

“With around 90 per cent of moulded products requiring textured finishes, we often use spark erosion. If a customer requires a certain VDI spark finish we design an electrode in VISI, bring our back-end Erowa block into the system and get it to the point at which it needs to be placed on the machine. It’s then manufactured on either the lathes or mills, and the form sparked in to give us the specified finish.” Because electrode production can be time consuming and complex, the VISI module creates and manages electrodes and their holders for detailed and hard-to-machine features.

Comprehensive holder design, simulation and collision checking form the quality control aspect of the process.

VISI PEPS-Wire is used where small, intricate inserts need to be wired into the mould tool. It provides automatic recognition of wire features from solid geometry, creating reliable wire EDM toolpaths and proven NC code.

Once the tools are built, Rutland Plastics’ uses its range of Engel and Krauss

Maffei injection moulding machines to produce a variety of components for the gas, water and petrochemical industries, agricultural products, electrical enclosures, the construction industry and automotive. Marketing Manager Stuart Lovett said: “The moulding operation runs 24 hours a day over a five-day week, manufacturing anything from just a few grams in weight, right up to a 710 mm electrofusion coupler weighing 48 kilos, which is our largest product.”

Although focusing on the mould tool itself, rather than part design, Rutland Plastics uses VISI to assist customers in ensuring their parts are suitable for injection moulding. As with the electrofusion pipe coupling, prototypes are often 3D printed on the Objet, with its 350 x 350 x 200 mm build tray, which also forms the basis of the 3D printing bureau service.

VISI Web: www.visicadcam.com

Meusburger releases DLC coated ejector pins with g6 tolerance

Application-specific medical mould innovations on show in China

Following customer requests, Meusburger, a manufacturer of standard parts for tool and mould making has broadened its product range with DLC coated ejector pins.

The DLC (diamond-like carbon) coating increases both wear resistance and corrosion resistance of the ejector pins, and their dry-running properties make them suitable for use in cleanrooms. In addition, the g6 tolerance enables simple installation into the mould, says the group.

Meusburger's range of ejector pins is available from stock.

Husky Injection Molding Systems, which recently completed the acquisition of mould-maker Schöttli, says that Schöttli is exhibiting at this year’s Chinaplas with mould technology for specific medical and specialty closure applications.

“Chinaplas has always been an important show for Schöttli and we are very excited to be exhibiting this year together with Husky,” said Thomas Anderegg, President of the Schöttli Group. “Asia Pacific is a growing market, particularly for medical moulds, and we are looking forward to the opportunity to connect with our

10 • WWW.EPPM.COM • APRIL / MAY 2014

Meusburger Web: www.meusburger.com

customers in this region and demonstrate the combined capabilities of Schöttli and Husky.”

Applications on display will include syringes, infusion/transfusion products, diagnostic systems and feminine care items. Also featured will be Husky’s EASYcube mould technology, a platform for moulding multi-material closures.

Husky Injection Molding Systems Web: www.husky.co/en-us/ Schöttli Web: www.schoettli.com

MACHINERY

Moulds & Tooling

Extrusion feedblocks can now be tuned during processing

Nordson Extrusion Dies Industries has developed a tuning insert for the Ultraflow I feedblock which can be adjusted during coextrusion. Tuning enables film and sheet processors to reduce downtime and material waste while permanent flow inserts are prepared. They also help processors achieve greater precision in the ultimate thickness profiles of each layer across the width of the die, claims Nordson.

The feedblock shapes molten polymer from two or more extruders into layers in a sandwich structure that is subsequently distributed to full end-product width inside a flat die. In feedblocks such as the Ultraflow I from Nordson Extrusion Dies Industries, a specially machined flow insert yields a target cross-direction thickness profile for each layer, and any job change involving significantly different layer ratios or polymer flow properties makes it necessary to design and machine different inserts. The tuning inserts for Ultraflow I feedblocks enable processors to maintain production while being adjusted until the target profile is achieved and a matching permanent insert can be built.

“The new tuning inserts help processors to maximise run time and minimise waste during the week or more that is required to design and machine permanent inserts,” said Sam G. Luliano, Chief Technologist at Nordson EDI. “Because the tuning inserts can be fine-tuned ‘on the fly,’ it is possible to do several iterations, making small additional

changes in very little time and refining the geometry with great precision before machining a permanent insert. This process eliminates the need to do several ‘re-cuts’ of the permanent insert before arriving at the target layer profile.”

Typically about 10 cm wide and machined from hardened stainless steel, a flow insert is specially designed to generate a corrective layer profile for a polymer with specific flow properties. The flow-adjusting component of the new tuning insert from Nordson Extrusion Dies Industries consists of ten segments, each of which can be adjusted to reduce or increase layer thickness by turning a corresponding screw. Once the target profile has been established, a measurement tool replicates the screw positions so that it can be used for producing a precisely matching permanent insert.

Ultraflow I fixed-geometry feedblocks can be designed to accommodate a flow sequencing spool that makes it possible to change the sequence of material layers without having to block off channels or disassembling the feedblock. Nordson Extrusion Dies Industries also offers the Ultraflow V adjustable-geometry feedblock, which, instead of interchangeable inserts, has built-in adjustable “combining planes” located where the melt streams join the central flow channel.

Static pinning system allows “powerful, repeatable” in-mould labelling The Meech Hydra is a miniaturised inmould labelling pinning system specifically designed for use in situations where small items are being moulded, designed by static specialist Meech. The 994 Hydra tackles issues encountered with other commonly used in-mould labelling technologies, helping to keep running costs low, claims the group.

“Meech has been involved in static control technology for decades and we’ve called upon that experience to develop a product that meets the requirements of OEMs and end users, many of whom are unhappy with the in-mould labelling options currently available on the market when dealing with smaller containers and labels,” said David Rogers, Business Unit Director for Static Control.

“The 994 Hydra system provides powerful, repeatable pinning with no degradation over time. Indeed, the operational life is almost indefinite. With this system, OEMs are free to make their own label carriers, which can be produced at a greatly reduced cost compared to some other IML technologies” said Rogers.

“The components of the 994 Hydra system are easy to mount, as well as being straightforward to connect and disconnect during mould tool changes.

The design eliminates the chance of sparking and the possibility of expensive damage to the mould tool. The choice of materials ensures that the problem of potential contamination of the container,

sometimes seen with conductive foam based IML systems, is removed.”

The standard 994 Hydra system consists of resistively coupled distributors connected in parallel to the new 994 IML generator. The distributors provide independent, spark-free operation of the pinning heads and have a mounting footprint of 50 x 86 mm. The pinning heads are 15 mm long x 5 mm diameter, making installation possible on the smallest label carriers.

“We’ve completely redesigned the static generator to create a simplified, lightweight model that generates the 20kV required for IML applications. The generator offers full remote control and reporting via the universal analogue facility. The easy to fit generator requires only a 24V supply and is light enough to be mounted on the end of arm tool, if required.”

Meech Web: www.meech.com

Nordson Extrusion Dies Industries Web: www.extrusiondies.com

Adval Tech bundles mould-making activities under Foboha brand The Adval Tech Group has consolidated all of its global mould construction activities under a single brand. With effect from 1 March 2014, Foboha Formenbau of Germany, AWM Mold Tech of Switzerland, Omni Industries Tech Center of China and Foboha US have been trading collectively as Adval Tech Foboha.

Foboha in Germany will continue to function as the technology center for mould construction, with a focus on multicomponent applications and cube technologies. Additionally the Swiss operation will continue to serve as a competence center for thin-section engineering. All sales activities of the four companies will be controlled by Foboha from Germany. The newly consolidated brand will be responsible for 350 employees globally.

Adval Tech Web: www.advaltech.com APRIL / MAY 2014 • WWW.EPPM.COM • 11

MACHINERY

Stratasys Ltd., a manufacturer of 3D printers and materials for personal use, prototyping and production, has announced that Robert Seuffer, GmbH & Co. KG (Seuffer), a German supplier of parts for household appliances and commercial vehicles, has incorporated Stratasys 3D printing in its manufacturing process to reduce the time and cost of producing injection moulded sample parts.

“Working with the automotive industry, sample parts need to be tested in the

Moulds & Tooling

environment of moving mechanical parts as well as in high temperature environments,” explained Andreas Buchholz, Head of Research and Development at Seuffer. “With Stratasys 3D printing, we can design first drafts of the injection mould within a few days and 3D print them in less than 24 hours for part evaluation. Traditionally, it would take eight weeks to manufacture the tool in metal using the conventional CNC process. And while the conventional tool costs us about 40,000 euros, the 3D

printed tool is less than 1000 euros, a saving of 97%.”

Using Stratasys 3D printing technology, Seuffer also produces 3D printed moulds for its hot melt process. These moulds, which are used to overmould low melting point polyamide over electronic circuit boards, are created with Stratasys’ rigid, opaque Vero materials.

“Companies worldwide are looking to introduce significant efficiencies to their manufacturing processes when introducing new products, and are

Two-stage ejectors offer simple stroke modification The use of two-stage ejectors is one of the ways in which complex undercuts on plastic parts can be demoulded. This seemingly straightforward mechanism, with its force-controlled and low-play movement, even permits the release of undercuts located inside the part.

Another use for two-stage ejectors is in moulds incorporating a stripper plate, or for the separate de-moulding of the sprue and the part.

Hasco supplies the Z1692/… two-stage ejector, to implement special series sequences, such as those required for inclined sliding carriage elements. These two-stage ejectors, which are designed for central installation, make it possible to define the two strokes that are required independently of each other. This

independence is achieved because the stroke of the three standard sizes, with maximum stroke lengths of up to 180mm, can be adjusted by means of a simple modification, claims Hasco. The group also supplies the two-stage ejector Z1692/… as a special, customised version with pre-set strokes.

The functional surfaces of all Hasco two-stage ejectors have a DLC coating to allow these products to be used in cleanrooms and for the production of devices for medical technology and the food industry. With its high hardness and slip properties, the

12 • WWW.EPPM.COM • APRIL / MAY 2014

polyamide with 65% glass-fibre content. This needs to be processed with a mould wall temperature of over 100°C. Temperature regulation in the mould needs to ensure a consistent temperature sequence as well as the positioning of the injection point to allow glass fibre orientation.

Specially coated steels are used to counteract the wear of the inserts by the high glass-fibre content.

During crash tests the manufacturer tested the lever’s durability in normal use as well as the predetermined breaking point for accident prevention. Due to extremely tight tolerances, the required lock function is guaranteed, says Braunform.

In terms of the appearance, the fine, eroded structure in the grip area and the offset-free transitions in the separation region are designed to give a high quality aesthetic.

Stratasys Web: www.stratasys.com

Software update tackles ECO obstacles for tool-makers

Since the conception of the lever, 16 injection moulds have been already been developed by Braunform, with the largest weighing 2.8 tonnes.

Cimatron, developer and distributor of software for the manufacturing industry, has announced the launch of a new feature in the latest version of its CAD/CAM solution.

The ECO Manager (Engineering Change Order) has been integrated into its CimatronE 11 software, a programme that provides specialised CAD capabilities for the design of moulds, dies and fixtures, as well as NC programming for the machining of moulds, dies and discrete parts.

“Engineering change orders (ECOs) are part and parcel of almost any tool shop job schedule,” said Ira Bareket, Cimatron’s VP Sales and Marketing.

“ECOs can become a cost burden, or can turn into a profitable business if handled and managed properly.

However, shops often find the process of handling ECOs to be challenging, particularly when there are many changes and the part is complex. The mould designer is faced with the difficult task of identifying the geometry the customer has changed, understanding ‘what’s going on’ and assessing the impact on previous work the designer has already undertaken,” he added.

Cimatron says the new ECO Manager provides mould designers with powerful tools and processes to handle ECOs in the quickest and most effective manner possible, including identification and analysis, implementation, tracking and documentation. “It can be used by shops at any stage of a job and can handle multiple ECOs, no-matter how complex,” concluded Bareket.

Braunform Web: www.braunform.com

Cimatron Web: www.cimatron.com

DLC layer helps to avoid abrasive and adhesive wear. This removes the need for lubricant.

Hasco Web: www.hasco.com

Complex slider mould developed for automotive lever application Braunform has developed a highly complex, mechanical slider mould for a lever application, which is manufactured by a well-known automobile supplier.

The 1- and 2-cavity injection moulds for the lever are subject to tolerances of +/2 µ. The lever has to fit in the architecture of the vehicle and the consumer has to be able to use it as a multi-functional instrument for gear shift and volume control.

The injection mould with three plate gating operates with several mechanical sliders in various angles in order to release the complex contour with holes and undercuts during the opening process of the mould.

By eliminating hydraulic movements, Braunform says that easier handling of the setup process as well as the production with high temperatures is possible. This is due to the customer’s request that the mould should be useable worldwide, including on machines which are not hydraulically equipped.

The material for the appplication is

discovering the many benefits of additive manufacturing, also known as 3D printing,” said Andy Middleton, General Manager, EMEA at Stratasys. “More and more manufacturers are adopting 3D printed tools as a complimentary injection moulding solution – not only to cost-effectively test products before mass production, but also to produce customised parts.”

MACHINERY

Blow Moulding

New Kautex series designed to boost efficiency Kautex Maschinenbau has launched a new machine series for blow moulded consumer packaging. The allelectric KBB series offers more freedom of configuration, allowing processor to react flexibly to changing market demands. Performance and energy consumption have also been optimised, claims the group.

“Our new generation of machines achieves its high performance levels through less downtime,” said Dietmar Michels, Product Manager at Kautex Maschinenbau. “We significantly accelerated transport movements in the machine as well as the opening and closing movement of the mould, reducing the traversing time for 770 mm from the head to the calibration position to only 0.6 seconds.” The cooling phase has also been shortened. Compared to conventional production systems, the new machine concept achieves a reduction of 25% in the dry cycle time.

Usually, higher performance requires even higher energy consumption, but Kautex says that this is exactly the opposite for machines of the KBB series. “By using lighter materials, we have significantly reduced the

moving mass. In this way, we were able to increase not only the performance, but also to reduce the required drive power,” said Michels. There is also a system for recovering energy where the excess braking energy is fed back into the machine or the processor’s network via an intermediate circuit.

A procedure for changing moulds, exclusive to Kautex Maschinenbau, allows for further efficiency improvements in the production process. A change of mould can be performed by two persons in less than 15 minutes. An automatic lubrication system provides for an additional reduction of downtime by reducing maintenance. All necessary adjustments for optimising material and the machine settings can be performed during operation. Consequently, the machine does not need to be stopped to adjust the closing or calibration forces. This simplifies handling and saves time, says the group.

Altogether, the four models of the KBB series offer feed strokes from 400 to 1,000 millimeters and closing forces

PET replaces glass in premium gastronomy bottle

Horners Bottlemakers Award 2014 now open

Kiefer GmbH, a specialist in research and development, design, and tool and die making has collaborated on a project for a PET bottle to replace the use of glass. The brief was to maintain the familiar and popular design of the glass bottle and adapt a design for a mould to manufacture PET bottles. The elaborate engraved logo in the glass bottle was also to be incorporated. Two sizes (0.5l and 1l) were to be made via rotary blow moulding. The bottle is made in dark blue PET and will soon be used in the field of international premium gastronomy.

As an independent mould maker, Kiefer says it manufactures blow moulds made of aluminum for rotary blow moulding machines from Krones, Sidel, KHS SIG, SIPA, SMI, plus linear blow moulding machines from ADS, Bekum, Kosme, MAG, Side, SIPA , Tetra Pak, and Arcor.

Kiefer Werkzeugbau GmbH Web: www.kiefer-mold.de

The competition for The Worshipful Company of Horners prestigious Bottlemakers Award in conjunction with the British Plastics Federation (BPF), is now declared open and entries must be received by the deadline of 25th July 2014.

Entries for this Award must be a plastic bottle, jar or hollow container, made by any process including extrusion blow, injection blow or injection stretch blow moulding.

Entries can also be injection moulding, vacuum forming and for the first time rotational moulded entries can now be submitted.

“The Bottlemakers Award is a prestigious accolade with a number of valuable commercial benefits attached. Last year we again saw a record number of entrants all demonstrating high levels of execution and exemplary creativity in design” said Keith Pinker, the Master of The Horners Company. The winner of the Horners Bottlemakers Award 2013 was APPE’s ThermaLite Hot-fill, Pasteuriseable PET Jar. The winner will be presented with their Award at The

from 10 to 40 tonnes, so that a wide spectrum of production options is covered. The manufacturer has also developed a new type of remote monitoring via the internet, as well as a virtual training station.

Kautex Maschinenbau GmbH Web: www.kautex-group.com

Mansion House during the annual banquet of the Worshipful Company of Horners, one of the City of London's most progressive Livery Companies. This year's banquet will take place on 2nd October 2014.

Application forms for the Bottlemakers Award are available to download from www.hornersaward.co.uk For further information, contact John Bunker via email john.bunker@btinternet.com and for more information about the Worshipful Company of Horners, visit www.horners.org.uk.

The Worshipful Company of Horners Web: www.horners.org.uk

Blow moulder cuts errors with plastic-specific ERP Matriplast, a producer of injection, blow and injectionblow moulded rigid containers based in Bolivia, has recently upgraded its in-house ERP software with a plastics-specific system, a move it says has helped it maintain and manage its business.

Having previously relied on its own internally developed ERP-type system, Matriplast says errors in reporting as a result of manually entering data across a number of sub-systems meant it was finding it increasingly difficult to get an overview of its business activity.

As a result, the company has installed a new, plastics-specific, Spanish-language ERP system from CyFrame, a Canada-based provider of software solutions exclusively for the plastic industry.

The ERP solution, created for the first time in Spanish at the request of Matriplast, consists of financial management, inventory and purchasing, production and distribution systems, as well as real-time, shop-floor barcode touch screen data acquisition.

CyFrame says its ERP was developed with the entire system being created simultaneously rather than piecemeal to run a business across all departments and collect, populate and cascade all data automatically.

The company says its knowledge of the plastics industry has enabled it to format relevant, in-demand reports that are vital to efficient operations.

Matriplast says as a result of the installation, it can now access accurate, current data and create reports in realtime to profitably run its business and better satisfy customers.

“To succeed in business in Bolivia, we have to adapt and be flexible and our ERP has to keep up with us,” explained Javier Alcoreza, Marketing Manager at Matriplast. “If you can’t follow the process in real-time from start to finish, you don’t have the information or tools required to properly manage your business.”

Cyframe Web: www.cyframe.com APRIL / MAY 2014 • WWW.EPPM.COM • 13

MACHINERY

News

BUSS adds to G3 kneader series The quantec 46 G3 is the latest addition to the BUSS quantec G3 family of kneaders. These high-performance kneaders are destined for compounding rigid and soft PVC. With throughputs up to 500 kg/h for compounding filled PVC, this smallest version offers flexibility and supports short change-over times for handling frequent formulation changes, claims the group. BUSS says that this makes it a cost-effective option for small to medium production runs. Its scalability of technical parameters also makes the quantec 46 G3 an ideal pilot line both for PVC producers and for prototype model testing in development and research applications.

The quantec G3 series covers PVC compounding throughputs up to 6000

kg/h with further sizes ranging through 60 up to 110 mm screw diameter. The machine is delivered as a turnkey compounding line, with all components from feed intake to control cabinet and pelletiser mounted directly on the baseframe. This minimises installation and commissioning time – only the power, water and compressed air supplies have to be connected. The unit has a footprint of about 30 square feet (3m²), and an ergonomic control layout.

Additionally, a built-in screw shaft temperature control significantly reduces energy consumption.

All quantec G3 sizes feature a combination of four-flight kneading elements on the axially oscillating screw shaft, with fixed kneading pins in the

kneader barrel. Together, these two design features intensify mixing while enabling a broad process window and high compounding throughput. PVC pellet quality can be optimised even further by adjusting the number and arrangement of freely configurable conveying, mixing and kneading elements on the screw shaft, claims BUSS. “We developed our new quantec 46 G3 to solve changing tasks fast and flexibly. This is a growing need particularly in the fast growing industries in Asia, where more and more small to medium enterprises are now challenged to combine high quality with an excellent

price/performance ratio”, said Wolfgang Walter, Head of Technology at BUSS. BUSS Web: www.busscorp.com

Coating for barrels, pipes and nozzles may replace heater bands Nordson Xaloy has launched a heater ‘coating’ which could take the place of heater bands for injection barrels, nozzles and melt pipes. The product is designed to maintain melt uniformity in extrusion melt pipes and adapters, and eliminate downtime for removing melt ‘blowback’ from injection nozzles.

Initially, the ‘SmartHeat’ coating was introduced specifically for injection barrels, but has since been adapted for nozzles. The coating can simplify maintenance and prevent the downtime caused by molten polymer oozing backwards (particularly when the seal is not tight) into the spaces between the heater bands and the nozzle. Available on new nozzles or as a retrofit, the coating is easily cleaned without need to stop production, claims Nordson.

In addition, the product has been used

on melt pipes or adapters. These components for transferring molten polymer from the extruder to downstream equipment can cover considerable distance, making it difficult to maintain melt uniformity. Nordson states that replacing band heaters with the continuous coating of the SmartHeat system ensures a consistent temperature over extended lengths.

Paragon Films, a processor based in the US, chose SmartHeat technology mainly to ensure uniform temperature control throughout its melt pipes. Gary Greenfield, Director of Engineering at Paragon Films said: “Anyone utilising band heaters knows the issues you can have with inconsistent heat transfer and the problems encountered when heater bands go bad,” said Greenfield. “We believe SmartHeat will eliminate these problems, not only providing a more reliable solution than band heaters but helping to reduce energy use as well.”

Moving moulds around the floor made safer with new device RUD Chains, a UK specialist in industrial lifting equipment, has launched a lifting point for use with large injection moulds that it says can minimise damage during movement as well as ensuring safety.

The PowerPoint Star is a robust lifting point which has the ability to pivot in any direction, allowing the lifting and turning of goods to run smoothly, as well as reducing costs to damaged tools. It offers a double ball bearing system that is said to provide a smooth and efficient swivel action when turning loads and is operational to temperatures as low as -40 degrees.

“The demand for loads to be turned, swiveled and twisted during the handling process of a project has increased over the years. Loads can easily be damaged and lifting systems can be considerably overloaded,” said the company. “Mould and die manufacturers are prime examples of this, when moulds or dies must be flipped the lifting points they use need to swivel and pivot at the same time.”

The forged safety latch on the PowerPoint Star is said to protect against lateral bending, as well as the thickened 14 • WWW.EPPM.COM • APRIL / MAY 2014

tip of the hook which prevents handling malpractices and resists bending, features that ensure safe handling when lifting and moving heavy goods. It also benefits from a ‘Clevis Fitting’, which allows three types of connections into the clevis; chain, hooks or, most commonly used, a master ring.

RUD Chains Web: www.rud.co.uk

The SmartHeat system consists of two layers of plasma-sprayed metallised ceramic with a nichrome wire wrap sandwiched in between, plus a thermal insulation cover. Because the heat from the wires is conducted throughout the ceramic material, Nordson claims that the system raises the temperature of a machine component to target levels more quickly than with band heaters, maintains it more uniformly, and uses less energy. The tightly strapped thermal insulation wrap over the ceramic coating is said to virtually eliminate heat losses to the workplace, saving on air conditioning costs and reducing the risk of operator injury.

“The SmartHeat system is 25 to 60% more energy-efficient than band heaters, and as a continuous coating it distributes heat more uniformly — a crucial

advantage for any melt pipe or barrel,” said David Hotchkiss, Global Product Manager for Nordson Xaloy. “Since all SmartHeat wiring is run underneath the thermal insulation, it eliminates the hazard of having numerous exposed wires connected to multiple heater bands.”

Nordson Xaloy Web: www.xaloy.com

Recycled tape can be converted into masterbatch

Recycling technology group Starlinger has developed a method for turning production waste from polypropylene tape lines into useable masterbatch, as well as a system for turning recycled PET and HDPE into food-contact approved materials.

Waste from polypropylene tape production is clean and homogenous, and is relatively simple to recycle, says Starlinger. With recoBATCH, the name the firm has given to its system, users can upcycle the waste by adding calcium carbonate. This can then be used to substitute some of the new masterbatch required in the tape production process.

The group will show a recoSTAR universal 65 VAC recycling line with the recoBATCH option at Chinaplas in Shanghai.

Starlinger will also display its viscotec line, set up with a deCON 20 decontamination dryer, for processing flakes and recycled pellets from PET and HDPE for use in food grade packaging.

The deCON 20 dryer can process input material in different forms – e.g. pellets, flakes etcetera – simultaneously. The process is compliant with the relevant FDA and EFSA standards, says Starlinger, meaning that the material can be used for food grade packaging.

Also designed for the food packaging market is the firm’s viscoSHEET line, which produces thermoforming sheets for food packaging from up to 100% recycled PET. Starlinger Web: www.starlinger.com

MACHINERY

News

SISE launches 180°C water temperature controller SISE has launched a new generation of pressurised water temperature controllers designed for custom applications in the automotive, medical, pharmaceutical, composites and technical components industries. These new products will be added to the SISE product line which the group claims, is the largest in the market for water and oil applications with heating power ranging from 6 to 200 kW for temperatures of 95° to 180°C (water) and up to 350°C (oil).

While the design is in-line with its latest generation of mould temperature controllers, SISE has integrated several

new functionalities. The 180°C is now the most compact of the SISE pressurised water temp controller product line.

Additionally, with a low water volume, this system is responsive to increases in mould temperature by using optimal thermal exchange. This results in a gain in energy during heating time. Lastly, the 180°C can be used for a large volume of water without problems with expansion.

This new generation of pressurised water systems was completely redesigned, and offers 6 to 60 Kw heating power, and 75 to 180 Kw for cooling power. Its modular construction makes maintenance easy

for the user, says SISE. A new 100l/min magnetically coupled pump and the integration of a new anti-tartar cooling system, guarantee superior functioning over time, claims the group.

The group also included a new colour touchscreen interface, displaying various alarms and programming cycles. The user is warned in real-time of any failure during the cycle.

SISE, which has locations in France, Germany and the USA, is a specialist in hot runner temperature control, water and oil mould temperature control, production monitoring, and valve gate

control for the plastics processing industry.

SISE Web: www.sise.fr

Event: Ferromatik Milacron open house

Ferromatik Milacron’s Open House, to be held 15-16 May 2014, will feature exhibits from a host of companies, including members of the growing Milacron brand.

DME, Mold-Masters, KORTEC, Uniloy Milacron and Cincinnati Milacron Extrusion Systems will all make an appearance at the event, alongside a total of 35 partner firms.

Running eight machines from the modular F Series with clamping forces ranging from 500 to 6,500 kN, Ferromatik Milacron will display a range of applications, with a focus on packaging, technical moulding and medical.

Different fitment variants will also be shown in function. Machines in the FSeries using hybrid or all-electric injection moulds will be in operation to demonstrate different production requirements. Ferromatik will also premiere the new F 580 with 5,800 kN clamping force.

Also new is the K-Tec Series with servohydraulic drive. A K-Tec 350 twocomponent machine will be displayed running a mono sandwich application.

In the all-electric Elektron Series, four machines with different clamping forces from 300 to 2,600 kN will be on display.

They are suited to standard applications and Ferromatik says they have an excellent cost to performance ratio.

Cincinnati Milacron Extrusion Systems and Uniloy Blow Molding will also show machinery running live at the event, including an extrusion plant for the production of WPC-decking boards and a UMIB 200 blow moulding machine. The key feature of the UMIB blow moulding machines is the EnergiaZero concept that can convert the kinetic energy of the clamp movement into electric power. The idea is based on the Kinetic Energy Recovery System (KERS) used in Formula 1 racing cars.

Ferromatik Milacron Web: www.ferromatik.com APRIL / MAY 2014 • WWW.EPPM.COM • 15

MACHINERY

News

Engel re-structures 'Engel Plus'

Piovan looks back on 50 years in plastics

Engel has reorganised its service packages and platforms for injection moulding machine owners, which are known collectively as ‘Engel plus’. The group says that the objective of the changes is “to create added value for customers and, thus, to improve their competitive advantage”.

Engel plus is now said to be more transparent, opening up further optimisation potential for existing machines, robots and plants.

“We accompany our customers through the entire production plant service life”, said Wolfgang Degwerth, Head of Engel Austria’s Customer Service Division.

“Total Cost of Ownership is becoming increasingly important for our customers. With Engel plus, we ensure optimal asset health and planning security for our customers and, on request, help them keep their machinery up to date at all times.”

Engel plus services include international on-site support with spare parts logistics, remote services and a 24/7 hotline, maintenance and repair contracts at fixed prices, retrofitting options and optimisation tools, application engineering consultancy and professional training and eLearning offerings.

“Above all, the topic of retrofitting is becoming increasingly important against a background of increasing efficiency pressure,” said Degwerth. Engel says that older injection moulding machines and control units can be improved in

Machinery and equipment group Piovan is celebrating 50 years in the supply of auxilliaries for the plastics sector. The group has more than 50,000 customers worldwide.

Piovan cites its “entrepreneurial ideas whose roots may lie far back in time, but which remain deep and active” as one of the key mechanisms for its longevity.

In 1934 Costante Piovan & Figli was founded in Padua as a metalworking shop equipped with machine tools, such as lathes and a few milling machines. The group took its name from its founder, Costante Piovan & Figli. Although Piovan was making moulds for prestigious companies, including Magrini Galileo (a major brand in Italy’s energy sector) he decided to focus the company on expanding into other markets, an approach which he derived from a customer-orientated philosophy.

The company has remained in the family through three generations of management.

terms of energy-efficiency, shot weight constancy and maintenance overhead minimisation. Engel plus also enables integration of additional process steps, technologies and automation. The supplier says it can also develop software packages on an individual basis.

More than 550 staff are employed in customer service and training at Engel’s global plants and subsidiaries. The company says that all service engineers and intructors are regularly required to take part in training and testing, some of which takes place via an online learning platform. “Short paths to our customers are very important to us,” said Degwerth.

“We are continually expanding our global service network.”

Engel Web: www.engelglobal.com

In 1964, Piovan launched its first piece of plastics processing equipment to the Italian market — a granulator and a material loader. Piovan has seen many expansions through the years, and now has production facilities in Italy, Germany, Brazil, China and the United States. The firm also has 21 subsidiaries, agents in more than 70 countries and 900 employees, of which 140 are customer assistance engineers.

The portfolio includes equipment for feeding, blending, drying and recycling systems, as well as industrial chillers and temperature controllers. Piovan equipment is integrated with proprietary production monitoring and control software.

The company says it looks to share knowledge with customers, acting not just as a supplier, but “as a partner working alongside customers and sharing their challenges.”

Piovan Web: www.piovan.com

Gas foaming added to cast film co-extrusion lines

Optiblo

™

Optiblo™ brings dynamic improvement to blow moulding processes • • • • • •

Enhances pigment dispersion Improves uniformity and dimensional stability Increases output and operates at lower temperatures Improves surface finish Significant reduction to cycle times Eliminates die lines

For more information, please contact us: t: +44 (0)1978 661496 e: info@silvergate.co.uk

16 • WWW.EPPM.COM • APRIL / MAY 2014

Film and sheet extrusion systems supplier Macro Engineering has added the option of including gas foaming into any layer of the multilayer film structures produced on its cast film coextrusion line.

Macro’s cast barrier film coextrusion system is used to produce multilayer film structures up to 11-layers and up to three metres wide using a variety of materials including PA, EVOH and PVdC. The films produced are most typically used in food and medical packaging applications.

“The addition of individual layer foaming broadens the possibilities of end-use applications”, said Andrew Erskine, Macro’s Marketing Manager. “Not only can foaming reduce weight and lead to raw material savings, but it can also create favourable properties in the film.

By foaming one or more layers embedded in the coextruded film, thermal and sound insulation can be improved, flexibility and conformability can be enhanced, and opacity can be obtained without using fillers.”

The cast barrier film lines can now be used for applications including thermoformed trays, insulation pouches, value-added lamination materials and stiffer, glossy films for shelf appeal.

Individual layer foaming is achieved with nitrogen gas injection through a feed-

block that distributes each layer of the melt flow. The feed-block’s design alleviates the need for a multi-manifold system that can add significant cost to the system, claims Macro Engineering.

The line can operate with or without foam injection, giving the film maker the option to switch between conventional multilayer films and foamed films without changing machinery configuration.

“Versatility is a driving motivation for us”, said Erskine. “Supplying systems with inherent flexibility helps our customers adapt to changing market demands. It also help mitigate risk on their capital investment”.

Macro recently installed a 7-layer cast coextrusion line in Europe that produces high barrier films with layer foaming in two of the seven layers and inline embossing to create an optimised product for the user’s end application.

Macro Engineering & Technology Inc. Web: www.macroeng.com

MACHINERY

News

BMW using KraussMaffei technology for the i3 KraussMaffei is supplying the injection moulding and reaction process machines used to produce the exterior parts made of thermoplastics and structural components made of fibrereinforced plastic on BMW’s electric car, the i3.

The company is helping BMW to process carbon fibre-reinforced plastics (CRP) for the first time in series production, with its injection moulding machines, swivel plate technology and the high-pressure resin transfer moulding process (HP-RTM) all being utilised.

“That is our contribution towards a new generation of vehicles in order to facilitate the breakthrough for lightweight construction and electromobility,” said Nicolas Beyl, President of the Reaction Process Machinery Segment of KraussMaffei.

KraussMaffei has supplied BMW with injection moulding and reaction process machines, including two double swivel plate machines that are fully automated with two industrial robots.

Weighing 400 tonnes, each MX 400017200/12000/750 WL is 24 metres long, nine metres wide and seven metres high. The thermoplastic outer shells of the BMW i3 are produced on these machines, which have a clamping force of 4,000 tonnes, at the BMW plant in Leipzig. Using the “joining in injection moulding” process, the outer door shell and its substructure are injected in a single pass, and joined as the two swivel

plates turn and are bonded with a third plastic component. “The combined work processes ensure very high dimensional accuracy of the parts,” said Frank Peters, Vice President of Sales at KraussMaffei.

In addition to the sidewall panels and the rear bumper, the hood of the BMW i3 comes from a KraussMaffei injection moulding machine. “They are produced on the most complex machines we have ever developed,” continued Peters.

In addition to injection moulding technologies and automation solutions, KraussMaffei’s Reaction Process Machinery Segment is also involved in the manufacture of parts for the BMW i3.

Some 20 machines for high-pressure resin transfer moulding (HP-RTM) supply reactive resin components for the supporting structures, for example the side frame, at BMW’s plants in Leipzig and Landshut. HP-RTM allows fast reacting resin systems to be processed in order to attain short cycle times. High-

pressure injection produces a high degree of fibre wetting.

In order to produce fibrr-reinforced parts with an epoxy matrix in larger series, KraussMaffei enhanced high-pressure resin transfer moulding (HP-RTM) for series use. In this process, a selfcleaning, high-pressure mixing head injects the resin into the closed cavity and saturates the fibres inside under high pressure and with precise stipulations of the duration and temperature so that the resin and hardener are fully networked. After it has hardened, the component becomes stiff and very light. KraussMaffei says compared with the previous autoclave process or vacuum infusion, the advantage of automated production is that the cycle times are reduced from up to 24 hours to minutes depending on the complexity and size of the component.

KraussMaffei says another advantage is

that this type of HP-RTM process is also suitable for the use of polyurethane instead of epoxy resin as a matrix material. In addition to easier handling of the generally lower raw material price, another advantage of polyurethane is the reduced processing temperature.

“With the BMW i3, we implemented our improved HP-RTM technology for the first time under series conditions within the context of a completely new production concept. This provides us with a broader view of the process chain in efficient fibre composite production and is our competitive edge for other projects”, said Josef Renkl, Head of Research, Development and Application Technology.

KraussMaffei Web: www.kraussmaffei.com

APRIL / MAY 2014 • WWW.EPPM.COM • 17

MACHINERY

News

Offshore transfer capsules made safer with rotomoulding Reflex Marine Ltd, a UK-based manufacturer of crew transfer technology for the offshore industry, is using rotational moulds from Midas Pattern Company to mould the first in a new generation of marine crew transfer capsules, the FROG XT4.

“Building on the success of our FROG transfer capsule, which we’ve been making for 15 years, we decided to develop an upgraded version, including new, additional features that would benefit our clients,” said Ken Poole, Supply Chain Manager at Reflex Marine.

“Our success has always been based on a commitment to innovation, staying close to our clients’ operations and collaborating with a range of industry partners, and we wanted nothing less for our new generation of crew transfer capsules.”

“I approached Midas and they gave me some indicative pricing which was far more competitive than other quotes we obtained in the wider marketplace,” he saod. “However, not only was the price attractive, but Midas come with a very high reputation and from experience I know they are very capable, and extremely nice people to work with, which counts for a lot in my opinion.”

Rotationally moulded plastic parts are suited to larger, more rugged applications where strength and size are a key factor. Midas specialises in complicated, multi-part rotational tools that include complex thread forms, loose pieces and sliding actions, for example.

The group’s tools can be purchased directly.

“Midas made tools to produce three different polyethylene parts: the onepiece external buoyancy unit, a very big moulding weighing around 35 kg; the

seat back; and the seat base,” said Mr Poole. “There’s four of each part in every XT4 crew transfer capsule.”

The external buoyancy units sit externally to the base frame of the capsule and are designed to offer the user more protection from potential impact. The units have to be capable of safely absorbing deck impact at up to 4.5 metres per second. The seats are also of a semi-saddle design to minimise any whiplash effects.

“Midas improved on their initial delivery estimate with each of the tools supplied, which was enormously helpful,” said Mr Poole. “Throughout the project Midas proved very responsive to my progress requirements. We were conversing almost constantly, maintaining a close and professional relationship. Midas made a number of suggestions relating to some of the finer design details, such

as where the split lines should go, and equally and just as critically, the position of the venting points. The external buoyancy units are extremely customer visible so aesthetics are vital. We relied on Midas’ knowledge of the rotational moulding process.”

Reflex Marine is now obtaining parts off all three rotational mould tools and is currently assembling the first XT4 units ready for imminent launch. In total, the company expects to produce 200-300 XT4 units every year, and intends to use the tools and parts in a modular manner moving forward.

“As with all our products, we continue to move crew transfer into a new and safer era, one in which risks to personnel are reduced drastically,” said Mr Poole.

Midas Pattern Company Web: www.midas-pattern.co.uk

Magnetic clamping delivers die change benefits Roemheld has launched a new magnetic clamping system that it says can reduce set-up and changoever times to two-tothree seconds, using a single clamp to install dies of all sizes.

Roemheld says the new M-TECS magnetic clamping plates provide a wide range of benefits compared with traditional mechanical, hydraulic or electromechanical systems.

The system has no moving parts and is basically maintenance-free, says the company. The full metal clamping surface of the elements enables users to avoid expensive standardisation of die sizes and clamping edge heights. The components are said to be suitable for vertical and horizontal use in machines and can be easily and quickly retrofitted onto most presses and punches. The plate thickness ranges from 47mm to 85mm (with an integral heating system) and the sizes and geometry of shapes can designed to meet a customer’s specific requirements.

Roemheld says its magnetic clamping technology is based on the principle of a permanent electric magnet, meaning it is safe even in the event of a power outage and, with a penetration depth of 15 to 20mm, does not impact on production.

Power is required for only one-to-two seconds to magnetise the system at the start. During operation, the system is independent of the power supply and

power is only required to unclamp the die.

Effective, full-surface magnetic forces of between 2 and 12 kg/cm² and clamping forces of between 500 and 2,000 kN act on the plates. The square pole magnets of the Roemheld plates ensure that even small dies are clamped without auxiliary devices. In addition, the full-surface clamping force ensures that the top and bottom die halves close reliably during the production process with no deformation, true to position and in parallel. This helps to reduce both wear and maintenance costs.

An additional control system permanently monitors the magnetic power, die position and temperature throughout the working process and the machine is brought to a standstill by even the slightest movement of one of the die halves.

Bill Neal, Joint Managing Director of Roemhel (UK) Limited, said: “In general terms, magnetic clamping systems are the best solution whenever frequent die changes are required, downtimes need to be reduced or it would be impossible or too expensive to standardise clamping edge heights and die sizes.

This technology is also suitable for large

die sizes and heavy weights, which require significant levels of power and a great deal of time to be clamped, for instance on large presses and punches in sheet metal forming. In these applications, magnetic clamping technology helps to cut unproductive set-up times.“ Roemheld Web: www.roemheld.co.uk APRIL / MAY 2014 • WWW.EPPM.COM • 19

MACHINERY

Markets: Compounding

Innovative solutions help manufacturers meet the demands of

EMERGING MEGATRENDS Words by Marcel Dartée, Global Marketing Director for Sustainable Solutions & Biomaterials, PolyOne Corporation Megatrends continue to drive the developments of manufacturers and the thermoplastics compounders who cooperate with them. A common theme across these megatrends is sustainability.

Specialty polymer solutions will continue to help manufacturers and plastics processors find sustainable solutions to challenges posed by these trends.

Readers of this magazine very likely have access to potable water, reliable healthcare, and a stable power supply.

However, much of the world’s population does not. The plastics industry can and will play a huge role in helping change that situation, with formulators of specialty polymer solutions – compounders taking on a critical role in the development of reliable solutions for these challenges.

Our company has identified four megatrends that pose great challenges, but also are a driver of dynamic innovation.

These trends are: • Improving health & fitness • Decreasing Dependence on Fossil Fuels • Protecting the environment • Globalizing & Localizing Let’s consider each of these points, and how specialty polymer solutions can play

a significant role in overcoming the challenges they pose.

Improving health and fitness Giant strides have been made in the past decades in healthcare. A girl born today in Western Europe, North America or Japan can expect to live into her mid-80s, and the outlook is improving in other parts of the world. This is good news, but as the percentage of elderly in the population increases, so too will the number of people requiring treatment for the illnesses that come with age.

Older people often have multiple chronic illnesses and disabilities, or they are simply frailer than others. They require devices and equipment tailored for physical limitations caused by conditions ranging from arthritis to chronic obstructive pulmonary disease (COPD) to osteoporosis. To provide adequate care to this growing patient pool, the healthcare industry needs safe, effective and cost-efficient tools. Going forward, treatment will be more often administered by the patient or caregiver at his home and not in a costly, acute hospital setting.

Ease of use and hazard avoidance are critical in home care scenarios.

New thermoplastic formulations help medical device manufacturers meet these challenges. For example, new grades of thermoplastic elastomers (TPEs) help ensure user-friendly ergonomic design of medical devices, diagnostics, equipment and packaging. Incorporating specialized

Globalizing & Localizing: Leading suppliers of thermoplastic formulations are able to support customers around the world, in even the most extreme locations.

20 • WWW.EPPM.COM • APRIL / MAY 2014

Protecting the environment: Plastics compounders support manufacturers with specialty polymer solutions to help them meet their sustainability goals.

Pictured is the Sunshine solar charger form Dutch manufacturer Xindao. materials into grips, handles, buttons, plungers, caps and closures can help reduce forceful exertion, repetitive motion, contact stress and vibration. Soft TPEs overmolded onto rigid thermoplastic substrates reduce “muscle effort” for a given operation such as turning a dial, pressing a lever or pushing a button. This ergonomic benefit can be quite important for seniors who have lost some or most of their muscular strength and control.

From a manufacturer’s standpoint, these advanced polymers also help streamline manufacturing steps. Eliminating secondary manufacturing operations via overmolding typically leads to energy savings and reduction of scrap, too.

Improved efficiency and a more sustainable solution are reached thanks to advanced polymer formulations.

Decreasing Dependence on Fossil Fuels Reducing dependency on fossil fuels is a major challenge. Advanced polymer solutions will help support developments in renewable energy sources, and also help improve the energy efficiency of homes, cars and other major users of fossil fuels.

Replacing metal with thermoplastics can reduce a products’ weight, and so reduce

the cost and fuel required to transport it.

Automobile manufacturers already face stricter guidelines on fuel consumption, and appliances are rated on their energy use. But the trend extends even to small consumer products such as mobile phones and MP3 players. These need to be stable, they need to be resilient to damage, and consumers want them to be lightweight.

Manufacturers are interested in metal replacement to reduce weight, but the final product also should be better, in terms of performance, aesthetics and carbon footprint, than a comparable metal one. We ask our customers, “What is important for the application? Must it be stiff, impact resistant, conductive, magnetic, or even all of these?” If suppliers of specialty polymer formulations have the opportunity to offer our expertise early in the development cycle, then we have seen that metal-toplastic transitions have a much higher degree of success. Our customers know their products and customers; we know our formulations and the most efficient way of processing them.

For example, we recently were approached by a manufacturer of automotive lights to help it with the redesign of its LED headlamp for construction and other heavy-duty

MACHINERY

Markets: Compounding are eco-conscious and easy to use.

Working together at the early stages of the design phase, PolyOne, Xindao and Xindao's design business, XD Design, developed all of the molded plastic casing components for its Sunshine solar charger using reSound biopolymer, which Xindao estimates will reduce the CO2 footprint for this product by as much as 35 percent compared to alternatives. The biopolymer solution was used to replace ABS, a thermoplastic derived from petroleum.

Globalizing & Localizing As manufacturers stretch their footprints across continents, they need both local supply as well as shipping of supplies

and end goods around the world.

Specialty thermoplastic formulators need to be able to support manufacturing where it happens, but also understand best practices for managing global supply chains. Cooperation between manufacturers and their suppliers can lead to improved sustainability, for instance by reducing the number of shipments required or by using customer specifications immediately to manufacture custom formulations formulations in multiple locations around the world.

Leading companies look to sustainable operations and practices as a means to better serve their customers and to improve their own business. Sustainability

is not a trend nor a charitable action, but rather a driver of innovation. Being sustainable is about making more safe, sellable product with fewer inputs — electricity, fossil fuel, and others.

Specialty polymer solutions, developed by manufacturers in cooperation with expert formulators, will help manufacturers reach their sustainability goals.

About the Author: Marcel Dartée is Global Marketing Director for Sustainable Solutions & Biomaterials at PolyOne Corporation.

PolyOne is a global leader in innovative polymer materials, services and solutions.

Learn more at www.polyone.com.

Improving health and fitness: A specialty thermoplastic elastomer ensures the grips of this syringe can be used even by patients with limited strength in their hands.

Decreasing dependence on fossil fuels: By replacing metal with a thermally conductive specialty polymer, Mars Otomotiv could reduce the weight on these LED lamps for heavy vehicles by more than 30% per part. vehicles. High Brightness Light Emitting Diode (HB LED) lights are much more efficient than incandescent bulbs at transforming electrical power into light.

But HB LEDs also are sensitive to high temperatures, so a heat sink is needed to dissipate heat into the surrounding air.

Effectively controlling the temperature helps the LED perform optimally for longer.

Metal heat sinks, usually of aluminum, are the current industry standard. With the support of PolyOne, Mars Otomotiv (Istanbul, Turkey) was able to transition to a specialty thermoplastic solution in just four months. Therma-Tech material, a thermally conductive specialty formulation from PolyOne, was chosen to replace the metal in this heat sensitive application. Manufacturing these heat sinks with Therma-Tech material solutions instead of aluminum helped reduce weight by more than 30% per part, and total part cost has been reduced by more than 20% while realising significant improvement in manufacturing efficiency.

Weight reduction and increased efficiency makes this a more sustainable solution.

Protecting the Environment Environmental sustainability involves making decisions and taking action to protect the natural environment, by reducing waste generated, reducing energy use, and also developing sustainable processes.

Leading manufacturers couple their sustainability goals with their financial goals, understanding that sustainable actions can also spur business growth.

An example can be found at Dutch-based Xindao, a leader in the promotional products industry. The company strives to differentiate with distinguished design and enduring, long lasting products that APRIL / MAY 2014 • WWW.EPPM.COM • 21

MATERIALS

Biopolymers

FKuR adds Bio PET and Bio PA for packaging applications FKuR has added to its bioplastic compound portfolio (which includes the Bio-Flex, Biograde, Fibrolon and Terralene brands), with a comprehensive range of distribution products. The group will present the new biobased products at Interpack in May. In addition to green PE (Bio-PE) from Braskem S.A., FKuR now also distributes Evonik‘s Vestamid Terra (Bio-PA) as well as Globio, a biobased PET. “With such a broad product portfolio, our customers now have the ability to access a unique variety of materials from a single source.” said Patrick Zimmermann, Director Marketing & Sales at FKuR. Differentiation from competitors is one of the main motivators for using bioplastics. “The immense product variety nowadays makes it more difficult for the producer to attract the consumer’s attention. With our bioplastics we offer the possibility of communicating ‘uniqueness’ using the packaging.” said Zimmermann.

FKuR says that it’s bio products come

with a host of specific functions.

For instance, the group says that compostable bags and singleuse catering items made from these materials can be disposed of together with food waste and organically recycled into valuable compost.

During Interpack, the group will also display the first production application for Bio-Flex F 6611, which has been converted to a new heatresistant thermoformed food tray. This fully compostable tray has been produced by Plastisud in Italy.

FKuR says that the range of potential applications for compostable products includes bags, pouches, nets and similar food packaging products.

For durable, non-biodegradable products, FKuR offers bio-based products such as Bio PE, Bio PET and

Bio PA. The group claims that as ‘dropin’ solutions, they have the same characteristics as their fossil-based equivalents and can be widely used in the packaging industry.

Laminates of Bio PE with Bio PET or Bio

PA can reportedly enhance the barrier properties of bioplastics and thus extend the shelf life for food products.

FKuR Web: www.fkur.com

PVC jacket compound uses bio-based plasticiser Teknor Apex has recently launched a new PVC jacket compound that is made flexible with a plasticiser based on renewable plant-based resources, which it says will help manufacturers of plenum cable to reduce their carbon footprint.

Fireguard FG 910B-01 plenum compound is recommended for Categories 5e and 6 LAN cable and fibre optic jackets. It uses phthalate-free Dow Ecolibrium bio-based plasticisers, which are manufactured using plant byproducts.

Plasticiser typically accounts for a large fraction of a flexible PVC compound, noted Mike Patel, Industry Manager for the Vinyl Division of Teknor Apex. “By incorporating into Fireguard FG 910B-01 a plasticiser that is based on a naturally occurring renewable resource rather than on petrochemicals, Teknor Apex has made a significant reduction of the carbon footprint in comparison with standard flexible PVC compounds,” Patel commented. “And since PVC resin itself is over 50 percent derived from

seawater, this new compound has much lower greenhouse gas emission potential compared to non-PVC alternatives.”

Teknor Apex says the RoHS- and REACH-compliant product includes no bromine or antimony flame-retardants and has a low VOC content. In tests for acid gas generation, Fireguard FB 910B01 compound is said to exhibit an acid gas content of 18%, which is below the 24-25% range that is typical for standard PVC.

Teknor Apex Web: www.teknorapex.com

Biome Bioplastics shortlisted for BusinessGreen Leaders Awards Biome Bioplastics, a leading developer of natural polymers, has been shortlisted for the BusinessGreen Leaders Awards 2014 in the Innovation of the Year category. The shortlisting recognises Biome Bioplastics’ work to develop a biodegradable coffee pod, offering one of the first sustainable packaging alternatives in the singleserve market.

Biome Bioplastics has developed a portfolio of compostable materials for coffee pods based on renewable, natural resources including plant starches and tree by-products. These bioplastics will degrade to prescribed international standards in composting environments.

Paul Mines, CEO of Biome Bioplastics commented: “Bioplastics are a vital component in the move towards a renewable resource future. Our coffee pod suite of products represent a significant step forward in plant-based polymer applications, tackling a major environmental challenge for a rapidly growing industry.

We are proud to have them recognised in the shortlisting of these prestigious awards.”

The BusinessGreen Leaders Awards are the UK’s most prestigious and coveted green business awards. Now in their fourth year, the awards celebrate the

leading businesses, executives, entrepreneurs, investors, and campaigners from across the green economy, highlighting how these pioneers are driving the emergence of

innovative and sustainable new business models and technologies.

Biome Bioplastics Web: www.biomebioplastics.com

PlastiComp and DSM develop bio-based thermoplastic composites PlastiComp, Inc., based in the USA, has signed a partnership agreement with Royal DSM, the global materials sciences company, to develop bio-based and sustainable long fibre thermoplastic (LFT) composite materials for the automotive and other performance-driven markets.

DSM’s experience in the biomaterials market comes from its EcoPaXX polyamide 410, which is 70% derived from renewable resources; PlastiComp is a specialist in LFT composites design and manufacturing. Initial compounding, 22 • WWW.EPPM.COM • APRIL / MAY 2014

moulding and testing of carbon-fibre reinforced EcoPaXX is reported to have been successful in establishing benchmark composites for hightemperature (up to 200°C) and structural applications.

DSM’s EcoPaXX polyamide 410 is 70% derived from castor oil, is said to have no adverse impacts on the food chain and is certified as carbon-neutral. The LFT composites PlastiComp is co-developing with DSM — which include compounds reinforced with glass fibre as well as carbon fibre — reportedly have an

excellent Life Cycle Analysis (LCA) score.

They are suitable for weight reduction applications in the automotive industry, targeted at fuel savings and lower emissions.

The two partner companies will also collaborate with potential customers to design injection-moulded composite parts. They will employ computer-aided engineering (CAE) tools for optimised fibre architecture in order to meet requirements for dimensional tolerances, surface finish, and high-temperature properties.

While the principal focus of the partnership is on automotive applications, composites that DSM and PlastiComp are developing are also attractive in other metal-replacement applications. Grades can, for example, leverage material characteristics such as electro-magnetic interference (EMI) shielding for electronics, and radiolucency in X-ray applications, enhancing the value of light-weight, high performance, metal substitutions.

PlastiComp Web: www.plasticomp.com

MATERIALS

News

Silvergate and Plastech chosen for Airfix ‘Quick Build’ range

Netzsch launches new DSC curve recognition and interpretation system

Masterbatch producer Silvergate Plastics has collaborated with UK-based Plastech Tooling and Moulding to produce ‘Quick Build’, the latest product range from iconic modelling kit brand, Airfix.

To engage with a younger audience, as well as existing fans of the traditional modelling sets, Airfix set about designing the range using push-fit construction technology and precoloured plastics. PlasTech was appointed the responsibility of injection moulding and product assembly and Silvergate was tasked with the development of the colours.

Unlike traditional modelling kits, the Quick Build range is manufactured using coloured plastics. As aircraft replicas,

Netzsch, a manufacturer of high precision instruments for analysis and testing, has launched new software for the automatic evaluation and identification of DSC (differential scanning calorimetry) curves when the technique is used for the recognition and quality control of polymer materials.

Netzsch has incorporated two new software solutions, ‘AutoEvaluation’ and ‘Identify’, into its instrument for the characterisation of polymers, the DSC 214 Polyma, which it says makes DSC investigations easier and more comprehensive.

The AutoEvaluation software allows for completely autonomous, reproducible and reliable evaluation of the measurements, where the Identify, single-click software significantly reduces the expertise needed to identify DSC curves, says the company.

For identification of polymer types, the software uses a database with with

the colours used had to be accurate, consistent and compliant with EN71 Toy Regulations.

“Technicians at Silvergate invested a great deal into the development of the colours to ensure they accurately replicated the aircrafts whilst complying with all necessary regulations relevant to toy manufacturing,” commented Mark Thompson, Operations Manager at PlasTech.

The Quick Build range won the prestigious Best New Toy award in the Hobby Category at this year’s London Toy Fair, presented by the British Toy and Hobby Association.

Silvergate Plastics Web: www.silvergate.co.uk

measurements and literature data from Netzsch libraries for polymers as a basis, as well as libraries that can be created by the user.

For application in failure analysis and quality control, using the DSC 214 Polyma with the Identify software can be used to analyse a DSC measurement on a rejected (broken) part, which can help to minimise product failures when used as a standard tool.

Netzsch Web: www.netzsch-thermalanalysis.com

APRIL / MAY 2014 • WWW.EPPM.COM • 23

MATERIALS

News

Sochi Olympic medals made from ‘crystal-like’ polycarbonate sheet The medals awarded to winners at the recent Sochi Winter Olympics were made using a combination of metal and durable polycarbonate (PC) sheet from Sabic’s Innovative Plastics business. The medals were made by skilled craftsmen of the Moscow-based Adamas Jewelry Plant using Lexan Margard sheet in the core.

The sheet was used in the core of the medals to design an intricate representation of the landscape of Sochi where the event was held. Each medal took up to 18 hours to create, using an assortment of design and technology processes. The Lexan Margard sheet was cut using a tool with incoming cold air to reduce deformation, resulting in a

‘crystal-like’ appearance. Lexan Margard sheet is 50% lighter than glass and has 250 times the impact resistance of glass and 30 times that of acrylic — Sabic claims that it is “virtually unbreakable”.

The sheet also displays weather performance characteristics and maintains its transparency over time.

1,300 medals were manufactured by Adamas, the official supplier to this year’s event and a major jeweller in Russia. Organisers said the design reflects the “eternal values of Russia” and also the “innovative approach to the games”.

Sabic Web: www.sabic.com

Compounder brings affordable ‘standard colours’ to market Burgess Colours & Compounds, based in Stoke-On-Trent, England has launched a new standard range, consisting of 36 universal 1% masterbatches, from white, through the colour spectrum to black. The colours are also available for next day delivery.

Burgess Colours Sales Director Tony Deaville said: “As a Director of Burgess Colours, I am honored to introduce this to our customers and potential customers. With this standard range we can meet their needs and provide them

with the best price.”

The group has been producing bespoke masterbatches into the plastics industry for 14 years.

Burgess Colours says it can also offer a large range of additive masterbatches at affordable prices, including lines for specific properties, such as UV, slip, anti-static and endothermic blowing agents.

Burgess Colours & Compounds Web: www.burgesscolours.co.uk

Bayer uses human biology for lightweighting technology Bayer MaterialScience is using the structure of human bones as a template to develop its latest technology for lightweighting in the productive of exterior automotive parts.

The company’s new technology is based on the development of components with a sandwich structure, taken from the way in which human bones are formulated and constructed.

At K 2013 Bayer showcased a prototype of a trunk lid that it said demonstrated the lightweight but ultra-stiff properties of its latest technology, designed to reduce the energy consumption of a vehicle whilst providing both the stability required and a smooth surface.

“With its smooth, dense outer skin and

foamed core, this part has a lot in common with a bone,” explained Ulrich Grosser, Team Leader for Advanced Technologies at Bayer MaterialScience.

“To make the outer layer, continuous glass fibre mats are impregnated with a thermoplastic polymer formulated from polycarbonate,” Grosser continued. “All the fibres are wetted and fully coated by the plastic matrix. This is the key to the high stiffness of the edge layers in a sandwich structure.”

In a second step, the top and bottom of the trunk lid are joined and the resulting hollow space is filled with Bayer’s ‘Baysafe’ polyurethane foam. Bayer says it is the very low density of the foam that makes the component so lightweight.

Since the foam is also very stiff, and adheres to the entire outer surface, the component is extremely resistant to minor damage.

“We passed a milestone in the efficient production of sandwich components with this materialbased design,” said Dr. Olaf Zöllner, Head of Application Technology for Polycarbonate.

“The auto industry often leads the way in pioneering technical developments, but we are also looking forward to talks with

customers and partners in other industries.” Zöllner said Bayer MaterialScience Web: www.materialscience.bayer.com

Thermally-conductive polymer replaces metal in LED lighting PolyOne is working with a global supplier of advanced lighting systems for the transportation industry that is using the company’s thermally conductive polymers to replace metal in the heat sink of LED lighting for construction vehicles, heavy trucks, and trailers.

Mars Otomotiv selected Polyone’s Therma-Tech polymers for replacing the metal parts in a move it says has significantly reduced total part cost, removed weight, and optimised its manufacturing and logistics.

“Mars Otomotiv is an industry leader, and to remain a leader we must continue innovating,” commented Abuzer Binici, a Director and Board Member of Mars’ parent company, Ayfar Otomotiv.

“Working with PolyOne introduced us to the opportunity to replace metal with advanced polymer formulations that can 24 • WWW.EPPM.COM • APRIL / MAY 2014

streamline our manufacturing processes and differentiate our products in the marketplace without compromising part performance.”

High Brightness Light Emitting Diode (HB LED) lights are much more efficient than incandescent bulbs at transforming electrical power into light, but also generate considerable heat. HB LEDs are sensitive to high temperatures, so heat sinks are often used to ensure optimal performance over time. Metal heat sinks, typically made of aluminum, are common, however they are heavier and more costly to manufacture than specialty polymer solutions.

By manufacturing HB LED heat sinks with Therma-Tech solutions instead of aluminum, Mars Otomotiv reportedly reduced part weight by more than 30 percent. Daily production rates were

increased by up to 50 percent and secondary operations, which were needed for the aluminum parts, were eliminated, reducing cost by more than 20 percent per unit.

Additionally, with technical support from PolyOne, the existing mould, which was used to cast aluminum parts, was able to be modified to mould the polymer heat sinks, eliminating the expense and delay of building tooling from scratch.

“The experts at Mars Otomotiv quickly recognized the innovative potential of Therma-Tech polymer solutions and worked closely with us to complete this project in less than four months,” said Holger Kronimus, Vice President Europe

and General Manager, Specialty Engineered Materials, Europe, at PolyOne. PolyOne Web: www.automotive.polyone.com

MATERIALS

News

Ferrari and Maserati choose flame retardant polyamide for fuel component DSM’s bio-based high performance EcoPaXX polyamide 410 has been selected by Dytech-Dynamic Fluid Technologies for the fuel vapour separators it produces for Ferrari and Maserati sports cars. The halogen-free flame retardant EcoPaXX grade Q-KGS6, will increase the fire safety of the cars by combining flame retardancy with a high level of chemical resistance.

The fuel vapour separator is a key element of the complete fuel delivery system in road vehicles. It separates vapours from liquid fuel coming out from the fuel tank, and prevents the liquid fuel reaching — and contaminating — the fuel vapour canister. This prevents the evapourating fumes from reaching the atmosphere while also maintaining proper fuel tank pressures.

While fuel lines themselves have a coextruded outer cover in a flame retardant thermoplastic, fuel vapour separators are most often still made from a non-flame-retardant polyamide. Dytech Dynamic Fluid Technologies, based just outside Turin, Italy, now part of Tokai Rubber Industries Ltd group, develops and supplies fuel delivery components and systems for many of the world’s leading automotive companies. Dytech chose the innovative halogen-free flame retardant EcoPaXX to meet increasing fire safety requirements as well as a wide range of other demanding requirements for the application.

EcoPaXX is highly resistant and impermeable to conventional gasoline

fuel (E10) as well as to the more sustainable E85 fuel, says DSM. In the SHED (Sealed Housing for Evapourative Determination) test, EcoPaXX fuel vapour separators showed a very low permeation level for E10, of 0.002 grams/24 h. EcoPaXX Q-KGS6 has a UL 94 V-0 flammability rating of 0.7 mm.

EcoPaXX can be used continuously at a maximum temperature of 175°C. The engineering grade also passed tube extraction and impact tests after thermal and fuel aging, as well as fatigue resistance.

“We have been very impressed by the performance we have obtained from the new EcoPaXX fuel vapour separators,” said Mario Zasa, Research & Development at Dytech. “Our customers make some of the most prestigious cars

BASF sells off “niche” liquid masterbatch business

on the road, and they call for top quality solutions from their suppliers. Working with DSM, we have succeeded again in meeting their demands.”

DSM claims that its engineering plastics are increasingly being used in various elements of automotive and nonautomotive fuel systems. For example, another grade of EcoPaXX, Q-HG6, has been tested successfully in automotive fuel line quick couplings, and Akulon Fuel Lock, a special grade of polyamide 6 for injection and blow moulding applications, provides resistance to permeation without the need for additives or post-moulding treatments in compressed natural gas tanks.

BASF has announced that it has signed a contract to divest its liquid masterbatch business in Clermont de l’Oise, France, to Audia International, a supplier of polyolefins and colour masterbatches. The transaction is expected to close in mid-2014.

BASF is now concentrating on its operations with solid and powder masterbatches, produced in Cologne, Germany. BASF says that liquid masterbatches are a niche business and not part of its future focus.

Audia’s acquisition is a strategic one, which it hopes will boost its entry into the European market over the past seven years. The liquid masterbatch business will be run as part of Audia’s subsidiary, Uniform Color Company, a global supplier of masterbatches, with facilities in North America and Europe.

The parties have agreed not to disclose financial details of the agreement.

DSM Web: www.dsm.com

BASF Web: www.basf.com

Report finds “numerous” safe plasticisers for PVC medical devices The Danish Environmental Protection Agency, the Danish Health and Medicines Authority and the PVC Information Council Denmark (a PVCMed Alliance partner) have disclosed the results of the report “Alternatives to classified phthalates in medical devices”.

The Danish Environmental and Health authorities are presenting the conclusions of this report which is based on the evaluation of ten existing PVC plasticisers. “The report concludes that most of the alternatives to DEHP that we evaluated for their human health and environmental hazard profiles are considered to be appropriate alternatives, but data are lacking for some of the alternatives, before a toxicological assessment can be carried out”, said Shima Dobel from the Danish Environmental Protection Agency.

The PVCMed Alliance partners provided data on these plasticisers to the Danish authorities. “Many different plasticisers have been developed and are increasingly being used in a wide array of medical applications allowing medical professionals to benefit from PVC’s

unique properties for patient comfort, economic affordability and hospital hygiene. We encourage the value chain to commit to continuous improvement of safety in order to develop innovative products for all PVC healthcare applications”, said Brigitte Dero, PVCMed Alliance representative.

The report outlines the need for certain types of medical devices to be “extremely soft and flexible” and “be able to offer the most efficient and qualitative treatment of patients”. PVC-based healthcare applications require an assortment of technical properties including flexibility and resilience, softness, sterilisability, chemical stability, biocompatibility, clarity and transparency, durability and dependability, resistance to chemical stress cracking, low cost, and many others.

“PVCMed believes this is a crucial discussion in order to continue ensuring patient safety and quality healthcare, even more so at a time of on-going review of the EU medical devices legislation and the SCENIHR (Scientific Committee on Emerging and Newly Identified Health Risks) scientific opinion on the use of phthalates in medical devices” said Ole Grøndahl Hansen, Director of the PVC Information Council Denmark and project manager for the PVCMed Alliance.

PVCMed Alliance Web: www.pvcmed.org APRIL / MAY 2014 • WWW.EPPM.COM • 25

MATERIALS

News

Temperature limit for perfluoroplastics raised with new grades DuPont Chemicals and Fluoroproducts has launched a new line of meltextrudable perfluoroplastics with continuous service temperatures of 300°C as well as fluoroplastic foam resins enabling miniaturisation and weight savings.

ECCtreme ECA is a class of meltextrudable perfluoroplastics which combines the mechanical, electrical and chemical properties of PTFE with high thermal stability. For instance, at a thickness of 0.75mm, the material has an RTI (Relative Thermal Index) listing of 300°C according to UL 746B. Thanks to its continuous service temperature of 300°C, ECCtreme ECA exceeds the previous upper limit of 260°C for conventional perfluoroplastic insulating materials, states DuPont.

“This development is our response to industry's challenge to offer a hightemperature, melt-extrudable perfluoroplastic”, said Frenk Hulsebosch, Global Business Leader at DuPont Fluoropolymer Solutions.

ECCtreme ECA grades can be processed on conventional extrusion equipment for high-temperature fluoroplastics using standard processing

conditions. Downstream heat treatment (epitaxial co-crystallisation) improves the material's thermal resistance and offers beneficial mechanical properties, such as long-term tensile modulus and improved stress cracking resistance.

The material is suitable for wire and cable insulations, which are exposed to extreme service conditions such as very high temperatures, elevated pressures and corrosive surroundings. Typical fields of application are the oil and gas industry, aerospace, energy generation, semiconductor fabrication and the automotive industry.

The group is also promoting Teflon fluoroplastic foam resins (FFR) produced using patented 'Airquick' technology.

DuPont claims that cables made with foamed fluoroplastic insulation have a lower signal return loss than conventional data cables, so enabling miniaturisation and weight savings thanks to lower density and thinner insulation thicknesses.

One current example is the new KL24 Star-Quad data cable developed for the aerospace industry by Draka Fileca of France, which won a DuPont Plunkett Award in 2013. It is up to 25% lighter than previously used quad cables, despite

have the same diameter, and enables a reduction in aircraft fuel consumption, so reducing environmental impact.

DuPont Chemicals and Fluoroproducts says that wire and cable insulation made using its products displays chemical resistance, good electrical properties and

thermal stability. Common features are dielectric strength, low permittivity, a low dissipation factor combined with low specific electrical resistance.

feedstock quality, and the integrated process scheme also reduces operating costs. The firms believe that Atol has significant potential to be integrated with both upstream ethanol production and downstream ethylene conversion.

Atol is the first of a series of technologies for the production of other olefinic monomers by processing bioderived higher alcohols, to be developed in parallel based on Atol’s technology platform.

“We are very excited about this efficient and competitive technology that will be able to meet a growing demand for plastics based on renewable rawmaterials. This offer is in line with our strategy to become a leading company in the field of technology for bio-based production of Motor Fuels and Chemicals”, said Christian Dupraz,

Axens Senior Executive Vice-President Process Licensing.

“For Total, such collaboration with a reputable research team (IFPEN) and a licensor (Axens), presents a significant lever to bring innovative technologies, driven by a fast-moving bio-market, to commercial readiness. This achievement can now open opportunities for industrial projects”, said François-Xavier Cormerais, Total’s Vice-President Research & Development (Refining & Petrochemicals).

“IFPEN is delighted that this exemplary partnership project has opened the way to a bio-ethylene competitive technology that is now ready for industrial implementation”, said Pascal Barthélemy, Executive Vice-President of IFPEN.

DuPont Web: www.dupont.com

New technology produces polymer-grade bio-ethylene Oil and chemicals giant Total in collaboration with catalyst specialist Axens, and research group IFPEN have launched Atol, a new technology for producing polymer grade bio-ethylene.

The collaboration claims that Atol is a platform for “the most profitable production of polymer grade bioethylene” by dehydration of 1G and 2Grenewable ethanol. The bio-ethylene produced can reportedly be integrated in existing downstream polymerisation installations such as polyethylene (PE), polystyrene (PS), polyethyleneteraphthalate (PET), polyvinylchloride (PVC) and acrylonitrilebutadiene-styrene (ABS) without need for modifications.

Atol is the result of a partnership between Total, IFP Energies nouvelles (IFPEN) and its affiliate Axens that started in 2011. Total developed a high

performance catalyst formulation at its research center in Feluy, Belgium. IFPEN scaled up catalyst performance within a heat recovery process while Axens industrialised the catalyst formulation and finalised the process scheme with particular focus on energy-efficiency.

Total and IFPEN are the co-owners of the technology and Axens is now in charge of commercialising Atol by providing all process licensing related services and catalyst manufacturing.

The groups claim that Atol is believed to be the most advanced dehydration technology and features the highest profitability as a result of lower capital expenditure due to simplified product purification brought on by the performance of the ATO 201 catalyst which exhibits a high activity and selectivity towards ethylene.

The catalyst copes with variations in

Total Web: www.total.com

Compounder claims “ultra performance” thermoplastic range Compounding group RTP Company has introduced what it describes as an “ultra performance” series of carbon fibre reinforced thermoplastic (CFRTP) compounds to its portfolio.

The company says the compounds are based on carbon fibre reinforced PEEK, PPA, PPS, and PEI resin systems to create the “highest performing” thermoplastic products available.

“Injection mouldable materials with this kind of performance are groundbreaking in their ability to open up new opportunities for using thermoplastics,” said Matt Torosian, High Temperature Product Manager at RTP Company. “We achieved this elevated performance by drawing upon RTP Company's knowledge and expertise in compounding high temperature polymers and fibre reinforcements to engineer a platform of products that raise the capabilities of thermoplastic 26 • WWW.EPPM.COM • APRIL / MAY 2014

compounds to new levels.”

Manufactured using advanced compounding techniques that maximise fibre integrity, RTP Company says the ‘Ultra Performance Structural Compounds’ achieve strength and stiffness properties that are higher than products previously available.

The company says that by combining the higher mechanical properties and lower densities of carbon fibre with the excellent thermal and chemical resistance provided by using high temperature resin systems, these injection mouldable thermoplastic materials close the performance gap between plastics and metals.

Products are available in high temperature resin systems with carbon fibre reinforcement loadings from 20 – 40 percent to provide performance options that meet a broad range of requirements for demanding applications in energy,

industrial, aerospace, automotive, and medical markets that previously required aluminum, zinc, and magnesium metals.

“These high temperature polymers combine excellent chemical resistance with very high strength and stiffness making them the premier choice for energy exploration, industrial fluid handling, and other applications that are exposed to harsh service environments.” said Torosian.

“These materials will allow more product designers to take advantage of the design freedoms plastics offer," added Torosian. "That translates into weight reduction opportunities, having the ability to overcome design limitations through part consolidation and optimisation, and to reduce manufacturing cost and shorten production time by obtaining net shape parts through a one-step injection moulding process that eliminates secondary operations.”

RTP Company Web: www.rtpcompany.com

MATERIALS

News

Arkema launching liquid resins for composite parts Arkema is launching its first range of liquid thermoplastic resins under the brand name ‘Elium’. Elium resins polymerise quickly and can reportedly be used to design structural parts as well as aesthetic elements in a number of applications in the automotive and transportation industries as well as the wind power, athletic equipment and construction markets.

“The name Elium is a great symbol that stands for an innovative brand in the community of material weight reduction.

Elium resins are multifunctional, lightweight, easy to use in manufacturing and high-performance,” said Sébastien Taillemite, responsible for the Elium

range. “They are based on conventional technologies and processes that processors were already using – an undeniably value-added product.”

Composite parts made from Elium are 30-50% lighter than the same parts made from steel, but offer the same resistance, claims Arkema. When combined with Arkema Luperox peroxide initiators, Elium can be moulded into complex designs for composite parts and the liquid blends with glass or carbon fibres.

It is also compatible with conventional thermosetting resin transformation technologies, including resin transfer moulding, infusion and flex-moulding.

Unlike unsaturated polyesters, Elium

resins do not contain styrene. Because they display thermoplastic properties, Arkema says that they can be used to design composite parts which can be easily thermoformed and recycled, with comparable mechanical performance to epoxy parts. Parts can be assembled via welding or gluing. Elium hardens at room temperature and it does not contain any fabricated products like organo-sheets.

In addition to the Elium range, Arkema is developing a polyetherketoneketone (PEKK) called Kepstan to replace metal in extreme conditions (offshore, aviation), the Rilsan range, a high-performance powdered or granulated polyamide that

is 100% bio-sourced and makes thermoset composites resistant to abrasion and shock at very high or low temperatures. Additives like Nanostrength, Orgasol polyamides and Luperox organic peroxides improve the natural resistance properties of composites. Lastly, AEC Polymers, an Arkema subsidiary specialised in structural glues and adhesives, markets BlackManba waterproof sealant adhesives and SAF structural adhesives – two ranges of bonding agents for complex composite assemblies.

Arkema Web: www.arkema.com

Eastman launches latest non-phthalate plasticiser in Europe Eastman Chemical Company has announced the availability of its new 168 SG non-phthalate plasticiser in Europe.

Eastman says 168 SG, which is an enhanced grade of its original 168 nonphthalate plasticiser, is specifically targeted for flexible PVC medical devices, as well as other highly sensitive applications including toys, childcare and food contact products.

In light of impending regulations in Europe, some OEMs are proactively making the switch to a non-phthalate plasticiser for their medical devices. For medical device OEMs, Eastman says the168 SG is a non-phthalate plasticiser that may be used as an alternative to

DEHP and tris (2-ethylhexyl) trimellitate (TOTM), and it is more efficient than using some of the other non-phthalate plasticisers available. Eastman says the product has extensive toxicological and regulatory profiles while remaining cost efficient. The plasticiser is said to have good performance properties, lowtemperature flexibility and excellent nonmigration properties.

“We are excited to bring to the European medical market a new nonphthalate plasticiser alternative that OEMs can easily start using in their medical products even before regulations mandate the change,” said Martin Stimpson, Global Market

Development and Key Account Manager, Adhesives and Plasticisers Business Unit, Eastman Chemical Company.

Eastman says 168 SG offers assurance of supply continuity and the most stringent quality assurance protocols, which are necessary for sensitive applications in the medical market. The plasticiser has high product purity, and customers also gain access to proprietary ISO 10993 and USP Class VI test data. In addition, the plasticiser is registered under REACH. Eastman Web: www.eastman.com

Celanese launches anti-counterfeiting portfolio Celanese Corporation, has launched a range of detectable polymer technologies targeted at anticounterfeiting.

The anti-counterfeit technologies are reportedly designed to help customers meet increasing security and safety needs by being able to detect the exact materials used in a particular product.

“Celanese is working with customers to help them meet their security and safety needs as they relate to protecting against counterfeiting,” said Stefan Kutta, Celanese Global Director-Transportation.

“These technologies are especially important today in light of several recalls

due to inferior and counterfeit materials.”

Celanese says its engineered materials are available with anti-counterfeiting technologies to help assist OEM and Tier suppliers in reducing the potential risk and loss of revenue from counterfeits in automotive parts, consumer products, medical devices, packaging and consumer electronics.

“Celanese material scientists have developed various traceability technologies to help customers avoid significant losses due to missed business opportunities, image-loss of brand, unwarranted claims for damages and patent infringements,” added Jos

Bastiaens, European Technology and Innovation Manager. “Celanese can provide different solutions for customised product protection through anti-counterfeiting features in plastics.”

Available anti-counterfeiting technologies include unambiguous part analysis based on unique engineered material additives; ultraviolet-detectable technologies for enhanced quality control that are primarily used in the production of complex medical devices; and printing and laser marking technologies that allow Celanese engineered materials to be marked with a visible barcode, such as manufacturer,

batch number and raw material/batch.

Other anti-counterfeiting technologies include X-ray detection, micro-tagging — invisible colour coded small particles — that can be identified via microscopy (10x magnification), and optical verifiable pigments/nanoparticles that are an invisible marker or “optical fingerprint.”

“Celanese is committed to helping its customers protect and enhance their brand,” Kutta said. “This portfolio of anticounterfeiting technologies can help them protect and grow their business.”

Celanese Web: www.celanese.com

New grades of PP developed for rotomoulders Due to the advantages offered by polypropylene (PP) for rotational moulding, Ultrapolymers has developed new grades it says offers increased benefits when using the material for the process.

The new grades are said to offer a combination of high stiffness (modulus of 1000MPa), excellent impact performance (55J Arm method), superior aesthetic appearance and easy processing, which Ultrapolymers says provides moulders with an invaluable opportunity to expand product ranges.

“Rotational moulders and designers are becoming increasingly interested in the properties offered by polypropylene. PP offers many advantages over PE, including increased stiffness, higher temperature performance, improved

ESCR, superior scratch resistance and higher gloss surface finish,” commented Ronny Ervik, European Technical Development Manager, Ultrapolymers.

“New grind specification and advancements in catalyst systems mean that converters can now get satisfactory results when processing PP on the same arm as PE, providing crucial commercial advantages,” he continued.

Some of the applications ideally suited to the PP grades include parts requiring autoclaving/sterilisation; high temperature processing; medical bio-technology; appliance housing; automotive; pipe system parts; furniture; and hot water systems.

Ultrapolymers Web: www.ultrapolymers.com APRIL / MAY 2014 • WWW.EPPM.COM • 27

APPLICATIONS

Packaging

3D in-mould technology leads to award-winning packaging

Injection moulded cocktail packaging deemed a West End showstopper

Trexel’s 3D in-mould labeling (IML) process for packaging applications has aleady won awards for packaging manufacturers since its introduction in 2012. The process enables the appearance of embossed labeling on the package without the associated tooling costs.

The “embossed” look comes from ‘3D’ labels applied during processing.

An application using this process, the Paccor/Unilever 500g polypropylene Margarine Tub with 3D IML, won the DuPont Packaging Silver Award in 2013 as well as the Emerging Technology award in SPI’s International Design Competition at NPE 2012.

The 3D in-mould label is processed with an injection moulded tub made of expanded polypropylene to incorporate selective masking, creating areas without adhesion. The MuCell process controls the introduction of nitrogen into the polymer. Where there is adhesion between the label and the polymer, the nitrogen migrates through both structures. Where there is no adhesion (by design behind the blue lettering), the nitrogen accumulates between the polymer substrate and the label. The process creates bubble patterns or Braille for a multi-sensory experience.

The margarine tub uses 6% less material than previously. Using the MuCell process also permits a 40% reduction in clamping tonnage, and a 15% reduction in cavity pressure, claims Trexel.

For the moulder, the process opens up opportunities to produce embossed

Stylish Tails cocktails is emerging as a key brand in the drinks industry, and one of the factors linked to the firm's success is cited to be its distinct choice of packaging, which was designed and engineered in partnership with RPC Containers.

Launched in early 2010, Tails says it sets out to “allow consumers to enjoy bar-quality cocktails in less than 30 seconds” and was initially aimed primarily at the at-home market.

Now, in addition to being made available through UK retail giant John Lewis in-store and online, Tails cocktails are being served in London’s West End theatres, where the packaging is displayed to create visual impact.

The packaging is designed to look and function like an authentic cocktail shaker. Consumers add ice, shake and serve.

Designed by Small Fry Design Studios, RPC Market Rasen developed the fourpart injection moulded lid, which allows the cocktail to be dispensed as it would be in a bar. The lid is assembled and then printed with a four-colour design at the Market Rasen factory, using a semiautomated four-colour Tampo printer.

RPC Blackburn manufactures the ISBM PET base, which is decorated with a shrink sleeve. The base is induction sealed after filling to give the product tamper evidence and shelf life.

Tails inventor Nick Wall said he wanted to allow consumers to enjoy high-quality

containers without extra tooling costs and no extra setup costs for the modifications. On a consumer level, Trexel says that creativity, differentiation and enhanced visibility on the shelf are the key benefits. In addition, the sensory impact on the feel of the packaging is being touted as a key benefit. The technology opens up new avenues in applying Braille to packaging for the benefit of visually impaired consumers.

Trexel claims that the process imposes no impact on recycling classifications. It also is reported to result in more dimensional stability, due to lower stress, and uniform shrinkage, which in turn leads to reduced warpage and fewer mould iterations.

Using the technology, Trexel says, means that companies can design wall thicknesses for function and appearance, instead of flow characteristics.

Trexel, Inc. Web: www.trexel.com

cocktails away from bars without needing lots of skill and a large drinks cabinet.

Wals said: “The pack not only allows consumers to experience the rite of creating a high-quality cocktail, it also helps provide a visually-striking point-ofsale feature.”

As well as being available in-store and online at John Lewis, Harvey Nichols and through Ocado, the cocktails are now on sale in Ambassador Theatre Group’s London venues including the Lyceum, Apollo, Piccadilly, Duke of York, Harold Pinter, Playhouse, Trafalgar Studios, Donmar, Phoenix and Fortune theatres.

RPC Containers Web: www.rpc-group.com

New automation set-up resolve dairy bottling issues A large Irish dairy has taken delivery of a new system to resolve handling problems with its bottling set-up. UKbased automation specialist Knight Warner has supplied the system.

To overcome various challenges, such as ensuring an adequate supply of the right type of milk bottle available at the right time, in the correct orientation and undamaged, Knight Warner, alongside Nampak, a UK producer of plastic milk bottles, has developed a handling system which delivers HDPE bottles to the milk filling heads at speeds of up to 500 bottles per minute.

Colin Powell, Technical Director at Knight Warner, said: “Our engineers designed a solution which was manufactured and tested in Chesterfield, Derbyshire and then shipped and installed into the dairy in Pennybridge.

“The key was in the integration of our patented ‘stripping system’ in conjunction with the latest PLC technology and sophisticated safety systems which allowed us to provide a solution which met all the requirements of the dairy, along with the installation of the equipment into the minimum possible footprint.”

The installation comprised of debaggers, conveyors, and management information system interfaces.

“Provision was made in the design to cater for the handling of Nampak’s new, award-winning lightweight ‘Infini’ bottle,” commented Jamie Tinsley, Nampak Plastics’ Commercial Director.

“The ability for remote access to the equipment allows continuous plant condition monitoring and produces efficiency performance data. It can also highlight alarm trips and fault codes, and maintenance requirements.”

Knight Warner Web: www.knightwarner.co.uk

New grade permits lighter caps and closures Borealis and Borouge has launched an advanced grade of the BorPure HDPE range designed to reduce weight in caps and closures. BorPure MB5568 has been designed specifically for the industry trend towards lightweight, standard short-neck closures (PCO 1881).

The Borstar platform is intended to permit the tailoring of PE mechanical and processing properties to match specific application requirements. The new grade displays improved stiffness and environmental stress crack resistance (ESCR) which potentially enables additional downgauging with consequent material and production cost savings, claims Borealis.

“Cost reduction in bottle production is a key factor in competitiveness for the 28 • WWW.EPPM.COM • APRIL / MAY 2014

beverage industry and lowering the volume of material used in caps is a focus element of that initiative,” said Russell Tew, Borealis Marketing Manager, Advanced Packaging and Fibre.

“BorPure MB5568 has been developed jointly by Borealis and Borouge to positively aid that objective by allowing converters and brand owners globally to further reduce the amount of plastic, which is contributing further to the costreduction initiatives taking place in the beverage industry.”

The group says that BorPure MB5568 offers excellent organoleptic properties and has no taste or odour influence on bottle contents – a parameter which is monitored to ensure batch-to-batch consistency. As a multimodal polymer,

BorPure MB5568 has a flow equal to that of benchmark monomodal MFR 2 HDPE resin.

“Borealis and Borouge, as the leading suppliers to the caps and closures industry, work continuously to identify changing market demands and deliver timely solutions that benefit the whole value chain from converter to consumer,” said Rainer Hoefling, Borealis Vice President Advanced Packaging and Fibre.

“BorPure MB5568 offers a new level of

packaging total cost performance efficiencies in line with that goal.”

Borealis Web: www.borealisgroup.com

INDUSTRY

News

OWEN MUMFORD CELEBRATES 25 YEARS IN GERMANY Owen Mumford GmbH (part of the Owen Mumford Group) recently celebrated 25 years of successful trading in Germany.

The modern sales office and warehouse are located in Großostheim, Bavaria, where the German team has been based for the last 10 years. From here the company provides a full packing and distribution operation allowing most of its customers to enjoy same day delivery.

General Manager Ralf Winter said he is very proud of how far the German business has come since 1989 when there was just one employee. Today the office is made up of nine highly trained full-time members offering marketing and sales services as well as technical support.

The mainstay of Owen Mumford’s business is the design and manufacture of specialist medical devices for the treatment of diabetes, and with six million people currently diagnosed with Type 1 diabetes in Germany alone — and numbers predicted to rise — Ralf Winter and his team are seeing an increase in demand for their products.

The German operation comprises two areas of business: original equipment manufacture, and the Owen Mumford

branded product range. The OEM business designs and manufactures custom-made devices for pharmaceutical and diagnostic companies who work with the group to produce specialist medical products for their customers, whilst the Owen Mumford brand is aimed at reaching patients through healthcare professionals at doctors’ surgeries, hospitals, pharmacies and blood banks.

Ralf Winter said: “When we first opened an office in Germany, OEM was the core business but 25 years later, we have a balance between Owen Mumford’s own branded products and OEM platforms. Our best sellers in Germany are the Unistik 3 safety lancets and our range of pen needles (used with insulin pens for injecting insulin).

“Our medical devices are designed to encourage patient compliance to help people better manage their medical conditions with patients being able to easily and safely test blood glucose levels as well as administer insulin injections from the comfort of their own home or while out and about. The OEM business is going from strength to strength with billions of dollars worth of drugs being delivered to patients all over the world using our autoinjector devices. It is likely that many patients in Germany will have used an Owen Mumford OEM device without ever knowing it.

“Over the years we have developed from a very small office to a substantial business and I’m delighted to say that 2013 was extremely successful for us. I am confident that as Owen Mumford GmbH expands, we will continue to play an important role in helping to improve patients’ lives.”

General Manager Ralf Winter toasts 25 years of busine ss in Germany.

New key appointment for the UK team Back at its headquarters in the UK, Owen Mumford

also recently announced the appointment of Judith Charles, who will take up the position of Sales & Marketing Director. As a member of the Executive Management Team, she will report directly to Jarl Severn, Managing Director, and will be responsible for leading the group’s sales and marketing function based at the company’s head office in Woodstock, Oxfordshire.

Judith’s career has spanned a range of disciplines including sales and business development, marketing and innovation particularly within international markets.

Prior to her new role, she enjoyed a successful career at Firmenich, a large private, family-owned Swiss company where Judith undertook a number of different roles including Marketing Director, Global Brand Director, Vice President of Product Development and Innovation and most recently as Managing Director of the UK operation.

Prior to Firmenich, Judith was European Sales & Marketing Director at RP Scherer where she developed close ties and sales growth with global blue chip companies, such as Unilever, Boots and L’Oréal.

Judith said of her new appointment, “I am thrilled to join Owen Mumford because their products offer people life-changing possibilities and I’m passionate about playing my role in this particular area of healthcare. I am especially excited by the company’s development within emerging markets and look forward to working with new teams of people in the world of specialist medical devices in both the UK and across the globe.”

Jarl Severn said, “We are very pleased Judith has joined us and feel certain her high calibre business knowledge will play a critical part in helping steer Owen Mumford towards its 2020 VISION. Judith’s expertise together with her considerable international experience will contribute significantly towards developing our sales and marketing strategy, helping to put Owen Mumford in an even stronger position within this highly competitive medical sector.”

Owen Mumford Web: www.owenmumford.com APRIL / MAY 2014 • WWW.EPPM.COM • 29

INDUSTRY

News

New technologies set to accelerate plastic film recycling Sam Haig, an IChemE member and Senior Engineer at Axion Consulting spoke at the 12th European Gasification Conference about new technologies in place to permit simpler recycling of plastic films and flexibles into fuels and other products.

Traditionally plastic bags and other lowgrade plastic film products are not widely recycled, due to difficulties with handling and sorting — instead, many international policies have involved bans or charges for consumers.

Axion Consulting, a UK recycling specialist says that recovery of plastic films is still in the early stages of development, especially in comparison to recycling processes for dense rigid

plastics such as polyethylene terephthalate (PET) used widely in the drinks industry. However, the group believes that new processing technologies may accelerate progress in the field.

Mr Haig said: “Plastic films are lightweight and 2D in shape and can easily get mixed into other recycling streams, such as paper, causing contamination.

“They also have a tendency to get trapped in recycling machinery requiring regular maintenance. As a result, plastic films have been excluded from most public household waste collection schemes around the world.

“However, a new generation of

machinery uses a flow of air to help detect and remove around 95% of films from co-mingled kerbside waste collections. The process is likely to be more economical and efficient than current machine-based and handpicking operations. Importantly, the recycled films can be used for products including refuse sacks and signage for retailers.”

Haig continued: “Our analysis also suggests that it is now economically viable to convert low grade plastics into fuel. We studied five chemical engineering processes and concluded that three: fast pyrolysis; depolymerisation; and gasification with biological treatment provided

significant financial returns over a ten year period.

“The more efficient sorting of films at recycling facilities and the conversion to fuels are clearly better solutions than disposal in landfills or by incineration.

However, avoiding irresponsible disposal in the first place and increasing our efforts to re-use plastic films and bags should be the priority for everyone.”

Sam Haig was speaking at the 12th European Gasification Conference in Rotterdam, The Netherlands, 10–13 March 2014.

Axion Consulting Web: www.axionconsulting.co.uk

Vinnolit puts R&D into PVC Europen producer of PVC, Vinnolit, has launched a range of new products in the field of paste PVC (P-PVC) that it says improve performance, energy efficiency and reduce cost.

“Vinnolit is one of the most innovative PVC manufacturers in the world and annually invests around 9 million euros in research and development and the application technology,” says Dr Wolfram Proessdorf, Commercial Director at Vinnolit.

For flooring, Vinnolit’s first new product, M 68 FW, is said to benefit from excellent

foaming properties and energy-and costsaving processing by contact gelation. Its copolymeric paste product, Vinnolit E 70 LF, can be used as gelling activator for the production of automotive underbody coating or flooring and is said to offer improved processing properties by its high storage stability and low viscosity.

For wallpaper applications, new Vinnolit E 67 FF is characterised by low viscosity, very good foaming properties in the sense of inhibition and very good filler tolerance. The new development Vinnolit E 75 HV can reportedly be processed to

high viscous plastisols, which are used for example for thermo-mechanically stable foam or for low-emission, coated artificial leather in the automotive interior.

“In all of our product developments our focus is on improving the product fit, that is performance, energy efficiency and cost reduction for the customer,” Proessdorf continued. “So we are working in research and development in close cooperation with our customers.”

Vinnolit Web: www.vinnolit.de

Spanish EP group Ferro adds European distribution UK-based polymer distributor Longfield Chemicals has announced a new partnership with Spain’s Ferro Engineered Polymer Products that will see it market and distribute the company’s range of products in the UK. Ferro Engineered Polymer Products’ operating from Castellón, Spain, is a major supplier of high quality

masterbatches and concentrates. The company, which is part of Ferro Corporation, headquartered in Ohio, USA, produces a range of coloured, white, black and additive masterbatches and concentrates for injection and blow moulding, film, sheet and profile extrusion and compounding.

“Ferro and Longfield are confident that

Ferro’s innovative and rapidly growing product portfolio and Longfield's dynamic approach to polymer distribution are well matched,” said the companies in a statement announcing the partnership.

Longfield Chemicals Web: www.longchem.co.uk

Clariant and Ashland to sell ASK Chemicals Clariant and Ashland Inc. have announced that they have entered into an agreement to sell their ASK Chemicals joint venture, which is headquartered in Hilden, Germany, to investment funds affiliated with Rhône, a London and New York-based private equity investment firm.

Clariant and Ashland stand to take approximately €149 million from the sale, and proceeds will be split evenly between the two firms under the terms of the 50/50 joint venture.

With 1,800 employees in 25 countries ASK Chemicals is a foundry chemicals manufacturer. Its portfolio includes binders, coatings, feeders, filters and release agents, as well as metallurgical

products including inoculants, inoculation wires and master alloys for iron casting. In full-year 2013 ASK Chemicals generated revenues of €513 million.

“The divestment of our stake in ASK Chemicals is part of our continuous active portfolio management to reallocate capital towards our more profitable growth areas,” said Hariolf Kottmann, CEO of Clariant. “In the joint venture we have successfully combined the activities of Ashland and former Süd-Chemie businesses. Now we release it to a new owner who will focus on growth perspectives.”

“The sale of Ashland’s equity interest in ASK Chemicals will allow us to focus

on our core specialty chemicals business as we reposition the company for sustained sales and profit growth,” said James J. O’Brien, Ashland chairman and chief executive officer. “At the same time, the divestiture will give ASK Chemicals an opportunity for new investment as it works to build on its position as a leading foundry chemicals manufacturer.”

Rhône commented: “We are proud to succeed Ashland and Clariant in the stewardship of ASK Chemicals. We are excited to be partnering with ASK Chemicals’ management team, and look forward to working with them to further develop the business in this

new phase of ASK's expansion, leveraging on its leading technology platform, long standing customer relationships, global manufacturing base and talented personnel.”

The transaction is expected to close during the third quarter 2014 and is subject to customary closing conditions, including regulatory approvals.

“Innovation Forum” for comapnies to display new products and services through short presentations, as well as a “Techno Lab” where visitors who may be new to the sector can learn more about the various processing techniques.

Other conferences and workshops will focus on new processes, materials, uses

and areas of research.

More details of the new exhibits can be found in the “Trade fair Essentials Book”, which can be accessed by visiting this link: http://we.tl/EgIVaWw6KJ.

Clariant Web: www.clariant.com Ashland Web: www.ashland.com ASK Chemicals Web: www.ask-chemicals.com

fiP solution plastique grows by 20% and adds third hall 700 exhibitors will be present at fiP solution plastique this year, which is a 20% increase on exhibitors and surface area in 2011. As a result, the event will use a third exhibition hall at the Lyon Eurexpo, and will be held from 17-20 June 2014.

The event caters for specialists in the 30 • WWW.EPPM.COM • APRIL / MAY 2014

fields of plastics, composites, rubber, machinery and equipment (including moulds and tooling and related services) as well as outsourcing services, which incorporate product design, component design, processing, and finishing/decoration.

The organisers are also holding an

fiP solution plastique Web: www.f-i-p.com

INDUSTRY

News

UK manufacturing showcase a success for prototype firm CMA Moldform, a UK-based company specialising in the development and manufacture of rapid prototypes - both one-offs and production runs - optical art moulding, centrifugal and vacuum castings, and high capacity rotacasting, in “Birmingham - We Still Make Things Manufacturing Showcase”, an event which took place at the House of Commons, in Westminster, London.

CMA Moldform was one of nine Birmingham companies that were asked to take part in showcasing the city’s

manufacturing ability. The exhibition, ‘Birmingham Day in Parliament’ was held on Wednesday March 5th in the Jubilee Room in the Houses of Parliament and was sponsored by the Birmingham Post, and City MPs from the three major parties who came together to host the event: Gisela Stuart (Lab Edgbaston), Andrew Mitchell (Con Sutton Coldfield) and John Hemming (Lib Dem Yardley).

There was a wide selection of MPs and other business leaders in attendance, with full coverage given on BBC and ITV

news programmes. Gisela Stuart, MP for Birmingham City unexpectedly held aloft a resin bird, manufactured by CMA, as an illustration during her speech.

Peter Turnock, MD of CMA said: “We were delighted to be invited to take part in the showcase. The growth and success of Birmingham and the resurgence of its manufacturing industry is something to be very proud of.”

CMA Moldform Web: www.cmamoldform.co.uk

Gisela Stuart and Andrew Mitchell with the helmet made by CMA Moldform Ltd for the film Prometheus.

DuPont extends distribution agreement with Alfa Chemicals for fluoroplastics Effective from 1st May 2014, Alfa Chemicals Ltd, Bracknell, UK, will become the official distributor for DuPont fluoropolymers (PTFE, PFA, FEP, ETFE) in the UK, Ireland, Finland, Sweden, Denmark and Norway. The agreement includes DuPont Teflon and Tefzel, as well as Zonyl PTFE micropowders (UK & Ireland) and Capstone surfactants and repellants (Nordics).

Those involved in pharmaceuticals, semiconductor, automotive, aerospace, electronics, general industrial, and homecare products will now be able to make use of Alfa Chemicals’ local sales coverage to access fluoroplastic resins from DuPont.

Marcel Vandennoort, Business Director DC&F, Europe, Middle East and Africa (EMEA) said: “Our channel partners play a crucial role in our efforts towards demonstrating and delivering to our customers the full value of Teflon Fluoroplastics and we are convinced that Alfa Chemicals is the right choice as our growth partner in these regions. Alfa Chemicals’ commitment to excellence and new-application development shares many synergies and complements our own strategy of delivering high-value solutions faster than ever before.”

Mark Walker, Managing Director of Alfa Chemicals adds: “We are pleased for the opportunity to further extend the scope

of our 20-year partnership with DuPont.

Following the recent successful expansion of Alfa into the Nordic region with the DuPont Capstone Fluoroproducts, we look forward to growing the Teflon Fluoroplastic business. To ensure that high standards of customer service and technical support are maintained, we will be increasing resources in the UK, Irish and Nordic regions.”

The range of high-performance solutions offered under the Teflon brand from DuPont Chemicals and Fluoroproducts is both broad and diverse; seeing multiple uses in demanding high- and low-temperature industrial applications across a great many industries.

Marcel Vandennoort, Business Director DC&F, Europe, Middle East and Africa (EMEA) Alfa Chemicals Ltd Web: www.alfa-chemicals.co.uk DuPont Web: www.dupont.com

AIMPLAS opens research centre for new materials and nanocomposites The Technological Institute of Plastics (AIMPLAS) has opened its new facility in the Technology Park Paterna, Valencia, Spain. The centre is destined for the research of nanomaterials, materials from renewable sources, composites and intelligent materials.

The new building has a total surface area of 4,500 m2 and is divided into three floors. With the new space, AIMPLAS will be able to increase the number of research projects that are implemented every year, not least because of its new equipment. Another objective will be an

easier transfer of the obtained know-how to the enterprises of the plastics industry in Valencia and throughout Spain.

At the moment, AIMPLAS is the only technology centre in Spain whose research and technological development activities are exclusively destined to plastic materials and their transformation processes. The group has a specialised research team, functional equipment for the processing of polymers and composites as well as an objective of transferring the knowledge to the improvement of the competitiveness in the plastics industry.

Researchers will have improved capacity to launch new projects related to high-value added plastic materials and transformation processes, as well as their usage in new applications in knowledge-intensive sectors, for example, packaging, the aeronautics sector, the automotive industry, the construction sector and the medical field. More

specifically, AIMPLAS will implement projects in relation to the development and improvement of renewable polymeric materials, nanocomposites, flame retardants as well as the improvement of their properties and processes.

Moreover, the group plans to develop new products, for example, active and intelligent packaging but also products based on recycled materials.

The design of the new building had a criteria with an emphasis on sustainability. Special attention has been paid to minimise the building’s energy consumption by obtaining the B-energyrating with an annual consumption of 49,000 kWh and annual CO2 emissions of 32,000 kg. Moreover, the use of the highest possible percentage of plastic materials has been considered in its construction, for example, EPDM rubber (ethylene propylene diene monomer rubber) for a waterproof roof coating, a sustainable material that is easily recycled and that permits to reduce the

energetic consumption, and also roof lights and false acrylic and PVC ceiling lights, expanded polystyrene and extruded polystyrene foam insulation or nylon carpets and PVC carpentry.

The façades, which are comprised of exterior plastic cladding, have been designed for an interesting and modern aesthetic, whilst at the same time providing a solar power monitoring system to contribute to energetic efficiency.

AIMPLAS Web: www.aimplas.es

Composites Germany joins the EuCIA Composites Germany, the trade association founded in 2013, has replaced the AVK - Industrievereinigung Verstärkte Kunststoffe e.V. (Federation of Reinforced Plastics) as a member of the EuCIA (European Composites Industry Association).

Through its membership of the EuCIA, Composites Germany will be able to 32 • WWW.EPPM.COM • APRIL / MAY 2014

represent the interests of the German composites industry even more broadly at the European level. Importantly, it also provides European representation for German companies operating in the area of high performance composites/CRP via the EuCIA. Dr. Elmar Witten, Managing Director of the AVK and Spokesman for the

Management of Composites Germany will retain his position on the board of the EuCIA. Composites Germany was founded by four major organisations in the German fibre reinforced composites industry: AVK - Industrievereinigung Verstärkte Kunststoffe e.V. (Federation of Reinforced Plastics), Carbon Composites e. V. (CCeV), CFK-Valley Stade e. V. (CFK-

Valley) and Forum Composite Technology in the VDMA (VDMA). With a total of over 750 member companies in these four organisations, Composites Germany is the largest national association under the European umbrella of the EuCIA. Composites Germany Web: www.composites-germany.org

Over 35 Years of Service

890mm wide Welex 3 roll polishing stack, anti stat bath, pump group, edge trim winders, haul off and 2 station winder. 1991.

Running Pet sheet from 150micron.

1300mm wide Battenfeld coextrusion sheet line; 2 x 90mm single screw extruders.

1300mm x 600mm 3 roll polishing stack+ haul, 2 station winder, 1995.

Tel: +44 (0) 1793 827666

115mm Davis Standard Thermatic extruder model 45IN45T . 30:1 L/D with barrier PP/ HDPE screw, 305kw motor, Fan cooled electrically heated 6 zone barrel 2008!!

Email: sales@transxl.co.uk

1350mm Welex 3 Roll Stack. 300mm Dia Rolls. Silent Chain. Dc drive. 3 zone pump group. 2 roll haul off 1986.

Web: www.transxl.co.uk

1120mm wide EDI close approach PET sheet die model H100 with Flex lip and decals. Lip heater. Lip gap up to 2.5mm 1996.

60mm Betol Extruder Model BK60. Approx 30kw dc motor and drive. 10 zone control pane. 25D non vented barrel. Serial number A8746.

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50mm Welex extruder 2300mm Sheet line for ABS

60mm BC60 extruder

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1500mm Bandera stack

90mm Kaufman extruder

1450mm Kaufman Sheet line 130mm + 63mm Davis Std coextrusion sheet line Upstream ; Comprising extruders, continuous s/changer, g/pumps, Cloeren Coex block & 1100 die, 2002!!

1350mm Welex/union sheet line 1300mm Battenfeld Sheet line 1000mm Omv sheet line

250ltr Motan Luxor 80 Dryer With Twin Desiccant Beds Which Provide Consistently Low Dew-point Air To Process, While Reducing Energy Consumption.

863mm wide EDI Ultraflex H75 flex lip sheet die. 0-1.9mm die gap. 480V heating.

115mm Davis standard extruder 130mm Davis standard extruder 150mm Egan extruder

1000mm Esde 3 rollstack

700mm wide Illig RDM 63/15B cup forming line with unwind stand, former, stacker, collator, rim roller, counter and sleever. 7oz 32 cav tool, 8oz cup tool 76mm.

890mm Welex 3 roll stack

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250mm Speedex vacuum unit

Summit Maguire WSB240

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Conair CD 30o dehumidifier unit

75mm wide betol Haul off

250ltr Motan units Conair Dehumidifying Dryer Model CD300 With Insulated Hopper, And Hopper Loaders.

CH44-58 hopper (1643 litres) 2002.

Colourtronic Gravimetric Blender

63mm Welex model 25-30D coextruder with screen changer, gear pump, melt pipe.

Control Panel mounted on extruder base.

Rapid 80/45 Granulator dual hopper, standard and nip roll feeder for sheet waste, 37Kw main motor, starter and blow back fan.2002.

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500mm wide Illig RDM 50/3 lid thermoformer, Double heaters, Motor Indexing. Auto Rail Spreading, Counter/ Stacker, 1982 very good condition.

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Boschaert chucks.Max roll diameter 1000mm. Dc motor control 2.2kw.

100mm Union single screw extruder. 35D vented with fan cooled barrel. Vacuum vent.

110kw dc motor and drive. Temperature panel 1987.

Betol servo cutter

4 component Ferlin gravimetric blender model FGB5-4 For up to 500kg/hr. Piovan hopper loaders.

1000mm wide Omv coextrusion sheet line.

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34 • WWW.EPPM.COM • APRIL / MAY 2014

EPPM Classif ieds

To advertise here please contact Lucinda Nicholls: T: +44 (0) 1244 680222 E: lucinda.nicholls@rapidnews.com

USED MACHINERY

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BLACK MASTERBATCH Compounding Pipe Film

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RE-PROCESSING EQUIPMENT

ADVERTISERS’ INDEX

eppm To advertise here, or place display adverts in print or online Contact Lucinda Nicholls Tel: +44 (0) 1244 680222 Email: lucinda.nicholls@rapidnews.com

Tel. 0049-2173-8950790 Fax 8950799 www.mhborowski.de info@mhborowski.de

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visit www.plastrep.com and join the world’s fastest-growing plastics community for free!

Company Abbey Masterbatch ACS/Cumberland AIMPLAS Albis asiamold Birmingham Granulators Buss CMA Moldform Colines Engel EPPM Hasco Industrierat Koch Technik Lanxess Maguire Maschinenhandel Borowski Meusburger Netstal Plastic Investments Plastrep PMH GmbH Process Control Rawmec RUD Chaines Silvergate Plastics S.i.S.e Tinius Olsen TransXL

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